ENGINE GENERAL

INFORMATION
0A

TABLE OF CONTENTS
CLEANNESS ............................................. 2 COOLING SYSTEM ................................. 16

ENGINE ASSEMBLY ................................. 7 FUEL SYSTEM ........................................ 17

LH side view .............................................................. 7 Fuel supply system ................................................ 18
RH side view ............................................................. 7
Front view ................................................................. 8 MAINTENANCE AND REPAIR ................ 19
Fan belt ..................................................................... 8 Maintenance and lubrication ................................... 19
Guidelines for service work safety ........................... 20
ENGINE CONTROLS ................................ 9
ECU related components .......................................... 9 OWNER INSPECTIONS AND SERVICES 25
Engine control system ............................................ 10 While operating the vehicle ..................................... 25
Electrical components and pre heating system ...... 12 At each fuel fill ........................................................ 25
At least twice a month ............................................ 25
INTAKE SYSTEM .................................... 13 At least monthly ..................................................... 25
At least twice a year ............................................... 26
EXHAUST SYSTEM ................................ 14 Each time the oil is changed .................................. 26
At least annually ..................................................... 26
LUBRICATION SYSTEM ......................... 15
STANDARD BOLTS SPECIFICATIONS . 27
2 0A

CLEANNESS

Cleanness of DI Engine Fuel System and Service Procedures

The fuel system for DI engine consists of transfer (low pressure) line and high pressure line. Its highest pres-
sure reaches over 1600 bar. Some components in injector and HP pump are machined at the micrometer 100
µm of preciseness. The pressure regulation and injector operation are done by electric source from engine
ECU. Accordingly, if the internal valve is stucked due to foreign materials, injector remains open. Even in this
case, the HP pump still operates to supply high pressurized fuel. This increases the pressure to combustion
chamber (over 250 bar) and may cause fatal damage to engine.
You can compare the thickness of injector nozzle hole and hair as shown in below figure (left side). The right
side figure shows the clearance between internal operating elements.

Valve actuator lift: 0.028 mm

Hair

Diameter: 0.40 mm
Operating
clearance:
Nozzle hole 0.002 mm
Diameter:
2.0 mm

The core elements of fuel system has very high preciseness that is easily affected by dust or very small foreign
material. Therefore, make sure to keep the preliminary works and job procedures in next pages. If not, lots of
system problems and claims may arise.

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GENERAL
Job Procedures
1. Always keep the workshop and lift clean (especially, from dust).

ASSY
2. Always keep the tools clean (from oil or foreign materials).

3. Wear a clean vinyl apron to prevent the fuzz, dust and foreign materials from getting into fuel system.

HOUSING
Wash your hands and do not wear working gloves.

4. Follow the below procedures before starting service works for fuel system.

EXHAUST I N T A K E
Carefully listen the symptoms and problems from customer.

Visually check the leaks and vehicle appearance on the wiring harnesses
and connectors in engine compartment.

LUB
Perform the diagnosis proceee with SCAN-100

COOLING
(refer to “DI10 DIAGNOSIS” section in this manual).

FUEL
Locate the fault. If the cause is from fuel system (from priming pump to
injector, including return line), follow the step 1 through step 3 above.

CONTROL
5. If the problem is from HP pump, fuel supply line or injector, prepare the clean special tools and sealing
caps to perform the diagnosis for DI engine fuel system in “DIAGNOSIS” section in this manual. At this

SENSOR
point, thoroughly clean the related area in engine compartment.

NOTICE
• Clean the engine compartment before starting service works.

Tool kit for high pressure line Took kit for low pressure line Removal tool box and cap kits

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6. Follow the job procedures. If you find a defective component, replace it with new one.

Disconnect the negative battery cable.

For safety reasons: check pressure is low before opening the HP systems (pipes)

Use special tools and torque wrench to perform the correct works.

Once disconnected, the fuel pipes between HP pump and fuel rail and between fuel rail
and each injector should be replaced with new ones. The pipes should be tightened to
specified tightening torques during installation. Over or under torques out of specified
range may cause damages and leaks at connections. Once installed, the pipes have been
deformed according to the force during installtion, therefore they are not reusable.
The copper washer on injector should be replaced with new one. The injector holder bolt
should be tightened to specified tightening torque as well. If not, the injection point may be
deviated from correct position, and it may cause engine disorder.

Plug the disconnected parts with sealing caps, and remove the caps immediately
before replacing the components.

Fuel Pressure Sensor

High pressure pump Common Rail

IMV valve
Low and high pressure pump High
Fuel temperature sensor Pressure
Pipe

Water separator
Water detection sensor
Priming
pump Label
(C2I)

Fuel
Filter

Injector

Sensors
HFM sensor
Cam position sensor
Fuel tank ECU Crank position sensor
Knock sensor etc.
Components:
Supply line
- High pressure fuel pump - Fuel rail - Fuel pressure sensor Return line
ECU communication line
- Fuel injectors - Electroc control unit (ECU) - Various sensors and actuators

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GENERAL
7. Plug the removed components with clean and
undamaged sealing caps and store it into the box
to keep the conditions when it was installed.
8. Clear the high pressure offset value by SCAN-

ASSY
100 after replacing the high pressure pump.

HOUSING
EXHAUST I N T A K E
9. To supply the fuel to transfer line of HP pump
press the priming pump until it becomes hard.

NOTICE
• Do not crank engine before having filled pump.

LUB
Priming pump

COOLING
FUEL
10. Check the installed components again and
connect the negative battery cable. Start the

CONTROL
engine and check the operating status.
11. With SCAN-100, check if there are current faults
and erase the history faults.

SENSOR
NOTE
• For details, refer to “Diagnosis table”.

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DI Engine and Its Expected Problems and Remedies Can be

Caused by Water in Fuel

SYSTEM SUPPLEMENT AGAINST PARAFFIN SEPARATION.

In case of Diesel fuel, paraffin, one of the elements, can be separated from fuel during winter and then can stick
on the fuel filter blocking fuel flow and causing difficult starting finally. Oil companies supply summer fuel and
winter fuel by differentiating mixing ratio of kerosene and other elements by region and season. However, above
phenomenon can be happened if stations have poor facilities or sell improper fuel for the season.
In case of DI engine, purity of fuel is very important factor to keep internal preciseness of HP pump and injector.
Accordingly, more dense mesh than conventional fuel filter is used. To prevent fuel filter internal clogging due to
paraffin separation, SYMC is using fuel line that high pressure and temperature fuel injected by injector returns
through fuel filter to have an effect of built-in heater (see fuel system).

SYSTEM SUPPLEMENT AND REMEDY AGAINST WATER IN FUEL

As mentioned above, some gas stations supply fuel
with excessive than specified water. In the conventional
IDI engine, excessive water in the fuel only causes
dropping engine power or engine hunting. However, fuel
system in the DI engine consists of precise components
so water in the fuel can cause malfunctions of HP pump
due to poor lubrication of pump caused by poor coating
film during high speed pumping and bacterization (under
long period parking). To prevent problems can be caused
by excessive water in fuel, water separator is installed
inside of fuel filter. When fuel is passing filter, water
that has relatively bigger specific gravity is accumulated
on the bottom of the filter.

If water in the separator on the fuel filter exceeds a certain level, it will be supplied to HP pump with fuel, so the
engine ECU turns on warning light ( ) on the meter cluster and buzzer if water level is higher than a certain
level.
Due to engine layout, a customer cannot easily drain water from fuel filter directly, so if a customer checks in to
change engine oil, be sure to perform water drain from fuel filter. (See fuel system for details.)

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ENGINE ASSEMBLY

GENERAL
LH SIDE VIEW

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
RH SIDE VIEW

CONTROL
SENSOR

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FRONT VIEW

FAN BELT

ENGINE GENERAL INFORMATION CHANGED BY

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 CHANGED BY

AFFECTED VIN
EFFECTIVE DATE
Brake fluid reservoir
Engine oil ABS/ESP
dipstick EGR valve
Coolant modulator
reservoir FFH Vacuum
pump
Vacuum
Oil separator
modulator
(PCV valve )
ENGINE CONTROLS

ECU RELATED COMPONENTS

Air cleaner Fuse box

assembly
Engine oil
filler cap

Battery

Washer
fluid
HFM VGT turbo
reservoir
sensor charger
Fuel filter &
priming pump
Engine PWM electric Power steering oil
fan & fan reservoir
shroud
0A

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ENGINE GENERAL INFORMATION
9

SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY GENERAL

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ENGINE CONTROL SYSTEM

The figures below show the components in the D20DT engine.

Engine Control System

Major Sensors and Components

Injector Glow Plug Common Rail

Camshaft Position Sensor Booster Pressure Sensor

Fuel Pressure Sensor

(Common Rail) Crankshaft Position Sensor

Common
Rail

Vacuum Modulator
Knock Sensor (1 EA) &
Water Temperature Sensor
Water temp.
sensor

Knock sensor

HP Pump

ENGINE GENERAL INFORMATION CHANGED BY

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 IP Interior Fuse Box (Passenger Side) Engine ECU Mounting Location Accelerator Pedal Module
Engine ECU Installed

CHANGED BY

AFFECTED VIN
main relay

EFFECTIVE DATE
VGT & EGR
vacuum
modulators,
HFM

Integrated
HP pumpIMV
with 2
Hazard warning
lamp
PPSs
Engine Accessories Related to ECU

Fuel Filter Sensor

HFM Sensor

Priming Fuel
Pump Filter

Service Interval (Fuel Filter)

EU Replace every 30,000 km (Draining water from
Only fuel filter: whenever replacing the engine oil)
0A

Replace every 25,000 km (Draining water from

General
fuel filter: whenever replacing the engine oil)

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ENGINE GENERAL INFORMATION
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 12

Glow Plug Preheat Warning Lamp (Cluster) Preheat Control Unit

0A

ACTYON SM - 2006.03
ENGINE GENERAL INFORMATION
No G5 for 4 IG1 power
cylinders terminal Glow plug control
(Without D20DT) signal(ECU113)

Ground
terminal

Battery
main wire

Glow plug K-Line Preheat completion transmit

terminal (#1 ~ #4) (ECU 34) terminal : No use for vehicle
Battery without remote engine start

Alternator Starter motor Engine

compart-
ment fuse
box
ELECTRICAL COMPONENTS AND PRE HEATING SYSTEM

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PTC / FFH:
12V - 115A 12V - 2.2kw
 Supplying Compressed Air with Intake Manifold

CHANGED BY

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EFFECTIVE DATE
Turbocharger’s Operation To corresponding cylinders
Coolant
port

Air
cleaner
INTAKE SYSTEM

Inter-
Turbo- From intercooler
cooler
charger

Recirculation of Exhaust Gas when

EGR Valve Operates

Intake outlet hose EGR valve

Air cleaner Intake com-
pressed air

Front air duct

Exhaust gas

HFM Sensor
Plug-in sensor Pretension Turbocharger Intercooler
graph

Terbocharger
intercooler

Air cleaner Turbo- Tempera-

0A

charger ture Sensor Uncompressed Compressed

air air

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SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY GENERAL

 14

PCV Oil Separator

0A

Cylinder head cover (oil + gas) DOC (Diesel Catalytic Converter) Exhaust Manifold

ACTYON SM - 2006.03
To turbo- To EGR
charger pipe

Blow-by gas
(air duct
hose)
Inlet port

ENGINE GENERAL INFORMATION

Oil (oil gauge From cylinders
pipe)
EXHAUST SYSTEM

The first separation will happen when

blow-by gas passes through baffle plates EGR Valve
in cylinder head cover. Then oil and gas will
be separated due to cyclone effect after
Intake com-
entering the oil separator inlet port. pressed air
Separated oil returns to oil pan via oil drain
port and the gas will be burnt again after
entering the combustion chamber through
air duct hose via PCV valve that opens/
closes due to pressure differences
between the intake side and crankcase. Exhaust gas

Turbocharger Vacuum Modulator

VGT Turbocharger

Vacuum
modulator
Turbo- Vacuum
charger pump
actuator

CHANGED BY
Engine ECU

AFFECTED VIN
To

EFFECTIVE DATE
exhaust (No. 95)
pipe
(DOC) IP interior fuse
EEGR Pipe box (RH)
Exhaust
Passage for recirculation of exhaust gas No.63(7.5A)
manifold
 PCV Oil Separator

Cylinder head cover (oil + gas)

CHANGED BY

AFFECTED VIN
EFFECTIVE DATE
Cylinder Head Cover Oil Pressure Warning Lamp (Cluster)

Blow-by gas
(air duct
hose)
Inlet port

Oil (oil
gauge
pipe)
The first separation will happen when
blow-by gas passes through baffle plates Cluster
in cylinder head cover. Then oil and gas will
be separated due to cyclone effect after
LUBRICATION SYSTEM

entering the oil separator inlet port.

Separated oil returns to oil pan via oil drain
port and the gas will be burnt again after
entering the combustion chamber through
air duct hose via PCV valve that opens/
closes due to pressure differences
between the intake side and crankcase.

Oil dipstick gauge

Oil Filter & Oil Cooler

Oil Pan and Baffle Plate (Integrated Type) Oil Strainer

Oil Oil
cooler filter
0A

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ENGINE GENERAL INFORMATION
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SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY GENERAL

 16

Coolant inlet hose Coolant Port

0A

ACTYON SM - 2006.03
Coolant reservoir

Return hose
Cool-
ant

ENGINE GENERAL INFORMATION

outlet
port
COOLING SYSTEM

Coolant outlet hose

PWM electric fan
Engine Oil Filter & Cooler

Oil cooler

Oil filter
cap

Radiator
Oil pressure
switch
Water Pump & Pipe Radiator Assembly Cooling Fan and Fan
Clutch
Cylinder block Thermostat (inside)

Oil cooler Oil filter

CHANGED BY

AFFECTED VIN
Radiator

EFFECTIVE DATE
Reservoir
(Coolant inlet hose)
 Injector Fuel Filter & Priming Pump

CHANGED BY

AFFECTED VIN
EFFECTIVE DATE
Fuel filter
FUEL SYSTEM

Priming
pump Connector

HP Pump

Cylinder Head

Fuel return hose Fuel return Fuel tempera-

Fuel pipe port
Fuel return port ture sensor

Fuel rail
pressure
sensor
IMV valve

Low pres- Venturi High pres-

sure fuel sure fuel
IMV
supply port supply port
connector
0A

High pressure
Common rail
fuel pipe

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ENGINE GENERAL INFORMATION
17

SENSOR CONTROL FUEL COOLING LUB EXHAUST I N T A K E HOUSING ASSY GENERAL

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FUEL SUPPLY SYSTEM

Fuel Pressure Sensor

High pressure Common Rail

pump

IMV valve
Low and high
pressure pump High
Fuel temperature
sensor
Pressure
Pipe

Water separator

Priming
pump
Label
(C2I)
Fuel
Filter

Injector

Sensors
HFM sensor
Cam position sensor
Crank position sensor
Fuel tank ECU
Knock sensor etc.

Components:
- High pressure fuel pump Supply line
- Fuel rail - Fuel pressure sensor
Return line
- Fuel injectors - Electroc control unit (ECU) - Various sensors and actuators ECU
communication line

According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accel-
erator pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based
on those signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position)
sensor determines injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal
that is generated by variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects
intake air volume and sends the signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recogniz-
ing instant air volume changes from air flow sensor to decrease the emissions (EGR valve control). Furthermore,
ECU uses signals from coolant temperature sensor and air temperature sensor, booster pressure sensor and
barometric sensor as compensation signal to respond to injection starting, pilot injection set values, various opera-
tions and variables.

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MAINTENANCE AND REPAIR

GENERAL
MAINTENANCE AND LUBRICATION

ASSY
Normal Vehicle Use Fuel Filter Replacement
The maintenance instructions contained in the mainte- Replace the engine fuel filter every.

HOUSING
nance schedule are based on the assumption that the 1. Gasoline Engine: 60,000 km (36,000 miles)
vehicle will be used for the following reasons: 2. Diesel Engine: 30,000 km (18,000 miles)
1. To carry passengers and cargo within the limitation
of the tire inflation prassure. Refer to “Wheels and Spark Plug Replacement

EXHAUST I N T A K E
Tire” in section 4H.
Replace spark plugs with same type.
2. To be driven on reasonable road surfaces and within
legal operating limits. 1. Type: BOSCH: F8DC4
BERU: 14F-8DU4
Champion: C11YCC
Explanation of Scheduled
2. Gap: 0.8 ± 0.1 mm
Maintenance Services
The services listed in the maintenance schedule are fur- Spark Plug Wire Replacement

LUB
ther explained below. When the following maintenance Clean wires and inspect them for burns, cracks or other
services are performed, make sure all the parts are re- damage. Check the wire boot fit at the Distributor and at
placed and all the necessary repairs are done before the spark plugs. Replace the wires as needed.

COOLING
driving the vehicle. Always use the proper fluid and
lubricants. Brake System Service
Check the disc brake pads or the drum brake linings.
Engine Oil and Oil Filter Change
Check the pad and the lining thickness carefully.

FUEL
Always use above the API SH grade or recommended
engine oil. Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equal-
Engine Oil Viscosity

CONTROL
ize wear and obtain maximum tire life, rotate the tires. If
Engine oil viscosity (thickness) has an effect on fuel irregular or premature wear exists, check the wheel align-
economy and cold weather operation. Lower viscosity ment and check for damaged wheels. While the tires
engine oils can provide better fuel economy and cold and wheels are removed, inspect the brakes.

SENSOR
weather performance; however, higher temperature
weather conditions require higher viscosity engine oils
Tire Rotation (Left-hand Drive Type)
for satisfactory lubrication. Using oils of any viscosity
other than those viscosities recommended could result
in engine damage.

Cooling System Service

Drain, flush and refill the system with new coolant. Refer
to “Recommended Fluids And Lubricants” in this section.

Air Cleaner Element Replacement

Clean the air cleaner element every.
1. Gasoline Engine: 15,000 km (10,000 miles)
2. Diesel Engine: 10,000 km (6,000 miles)
Replace the air cleaner element every.
1. Gasoline Engine: 60,000 km (36,000 miles)
2. Diesel Engine: 30,000 km (18,000 miles)
Replace the air cleaner more often under dusty conditions.
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GUIDELINES FOR SERVICE WORK SAFETY

General Cautions on Inspection/Service

NOTICE
During service works, be sure to observe below
general items for your safety.
• For service works, be sure to disconnect battery
negative (-) terminal if not starting and inspection.
• While inspecting vehicle and replacing various
consumable parts, be sure to take caution not to
damage vehicle and injure people.
• Engine and transmission may be hot enough to
burn you. So inspect related locations when they
cooled down enough.
• If engine is running, keep your clothing, tools, hair
and hands away from moving parts.
• Even when the ignition key is turned off and posi-
To maintain and operate the vehicle under optimum state tioned to LOCK, electrical fan can be operated
by performing safe service works, the service works while working on near around electrical fan or ra-
should be done by following correct methods and diator grille if air conditioner or coolant tempera-
procedures. ture rises.
• Every oil can cause skin trouble. Immediately
Accordingly, the purpose of this manual is to prevent
wash out with soap if contacted.
differences that can be caused by personal working
• Painted surface of the body can be damaged if
method, skill, ways and service procedures and to al- spilled over with oil or anti-freeze.
low prompt/correct service works. • Never go under vehicle if supported only with jack.
Note, Notice • Never near the battery and fuel related system to
flames that can cause fire like cigarette.
While using this manual, there are a lot of Note or No- • Never disconnect or connect battery terminal or
tice having below meaning. other electrical equipment if ignition key is turned
on.
NOTE • While connecting the battery terminals, be cau-
tious of polarities (+, –) not to be confused.
• Note means detailed description of supplemen-
tary information on work procedure or skill. • There are high voltage and currency on the bat-
tery and vehicle wires. So there can be fire if
short-circuited.
• Do not park while running the engine in an en-
NOTICE
closed area like garage. There can be toxication
• Notice means precautions on tool/device or part with CO, so make sufficient ventilation.
damages or personal injuries that can occur dur- • The electrical fan works electrically. So the fan
ing service works. can be operated unexpectedly during working
causing injuries if the ignition key is not in LOCK
position. Be sure to check whether ignition key is
However, above references and cautions cannot be in- in LOCK position before work.
clusive measures, so should have habits of taking con- • Be careful not to touch hot components like cata-
lytic converter, muffler and exhaust pipe when the
cerns and cautions based on common senses.
engine is running or just stopped. They may burn
you badly.

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GENERAL
Guidelines on Engine Service Fuel and lubrication system
To prevent personal injuries and vehicle damages that Painted surface of the body can be damaged or rub-

ASSY
can be caused by mistakes during engine and unit in- ber products (hoes) can be corroded if engine oil and
spection/repair and to secure optimum engine perfor- fuel are spilled over. If spilled over engine, foreign
mance and safety after service works, basic cautions materials in air can be accumulated on the engine
and service work guidelines that can be easily forgotten damaging fuel system.

HOUSING
during engine service works are described in. 1. If work on the fluid system such as fuel and oil,
working area should be well ventilated and mechanic
Cautions before service works should not smoke.

EXHAUST I N T A K E
1. Before work on engine and each electrical equipment, 2. Gasket or seal on the fuel/lubrication system should
be sure to disconnect battery negative (-) terminal. be replaced with new and bolts and nuts should be
2. Before service works, be sure to prepare the works tightened as specified.
by cleaning and aligning work areas. 3. After removal/installation works, be sure to check
3. Always position the ignition switch to OFF if not whether there is leak on the connecting section.
required. If not, there can be electrical equipment
damages or personal injuries due to short-circuit or
ground by mistake. If fine dust or foreign material enters into DI engine’s

LUB
fuel system, there can be serious damages between
4. There should be no leak from fuel injection system
HP pump and injectors. So, be sure to cover removed
(HP pump, fuel hose, high pressure pipe) of the
fuel system components with cap and protect removed
D20DT & D27DT engine. So they should be

COOLING
parts not to be contaminated with dirt. (Refer to clean-
protected from foreign materials.
ness in this manual while working on DI engine fuel
5. While removing the engine, do not position the jack system)
and others under the oil pan or engine. To secure the
safety, use only safety hook on the engine.

FUEL
Engine and accessories Electrical equipment
Engine has a lot of precise portions so tightening torque Electrical equipment should be handled more carefully.

CONTROL
should be correct during disassembly/assembly and re- Currently, the engine is equipped with a lot of electrical
moval/installation and service work should be done in equipments so there can be engine performance drops,
clean ways during disassembly/assembly. incomplete combustion and other abnormals due to short
Maintaining working area clean and cautious service ad- and poor contact. Mechanics should well aware of

SENSOR
ministration is essential element of service works while vehicle’s electrical equipment.
working on the engine and each section of the vehicle. 1. If have to work on the electrical equipment, be sure
So the mechanics should well aware of it. to disconnect battery negative (-) terminal and
1. While removing the engine, related parts (bolts, position the ignition switch to off if not required.
gaskets, etc.) should be aligned as a group. 2. When replacing electrical equipment, use the same
2. While disassembling/assembling internal components genuine part and be sure to check whether ground or
of the engine, well aware of disassembly/assembly connecting portions are correctly connected during
section in this manual and clean each component installation. If ground or connecting portion is
with engine oil and then coat with oil before installation. loosened, there can be vehicle fire or personal injury.
3. While removing engine, drain engine oil, coolant and
fuel in fuel system to prevent leakage.
4. During service work of removal/installation, be sure
to check each connected portions to engine not to
make interference.

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During Service Work - Inspection

1. Before lifting up the vehicle with lift, correctly support
the lifting points and lift up.
2. When using a jack, park the vehicle on the level
ground and block front and rear wheels. Position
the jack under the frame and lift up the vehicle and
then support with chassis stand before service work.
3. Before service work, be sure to disconnect battery
negative (-) terminal to prevent damages by bad wire
and short.

4. If service from interior of the vehicle, use protection

cover to prevent damage and contamination of seat
and floor.
5. Brake fluid and anti-freeze can damage painted
surface of body. So carefully handle them during
service work.

6. Use recommended and specified tools to increase

efficiency of service work.
7. Use only genuine spare parts.

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 0A 23

GENERAL
8. Never reuse cotter pin, gasket, O-ring, oil seal, lock
washer and self-locking nut. Replace them with new.

ASSY
If reused, normal functions cannot be maintained.
9. Align the disassembled parts in clean according to
disassembling order and group for easy assembling.

HOUSING
10. According to installing positions, the bolts and nuts
have different hardness and design. So be careful
not to mix removed bolts and nuts each other and
align them according installing positions.

EXHAUST I N T A K E
11. To inspect and assemble, clean the parts.
12. Securely clean the parts that related with oil not to
be affected by viscosity of oil.
13. Coat oil or grease on the driving and sliding surfaces
before installing parts.
14. Use sealer or gasket to prevent leakage if necessary.
15. Damaged or not, never reuse removed gasket.

LUB
Replace with new and cautious on installing
directions.
16. Tighten every bolt and nut with specified torque.

COOLING
17. When service work is completed, check finally
whether the work is performed properly or the problem
is solved.

FUEL
18. If work on the fuel line between priming pump and
injector (including return line), be sure to cover the
removed parts with cap and be careful not to expose

CONTROL
the connecting passage and removed parts to
external foreign materials or dust. (Refer to
cleanness.)
19. If remove high pressure fuel supply pipe between

SENSOR
HP pump and fuel rail and high pressure fuel pipe
between fuel rail and each injector, be sure to
replace them with new.

CHANGED BY ENGINE GENERAL INFORMATION

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
24 0A

During Service Work for Electric Devices

NOTICE
• Be careful not to modify or alter electrical system and electrical device. Or there can be vehicle fire or
serious damage.

1. Be sure to disconnect battery negative (-) terminal during every service work. Before disconnecting battery
negative (-) terminal, turn off ignition key.
2. Replace with specified capacity of fuse if there is bad, blown or short circuited fuse. If use electrical wire or steel
wire other than fuse, there can be damages on the various electrical systems. If replaced with over-capacity fuse,
there can be damages on the related electrical device and fire.
3. Every wire on the vehicle should be fastened securely not to be loosened with fixing clip.
4. If wires go through edges, protect them with tape or other materials not to be damaged.
5. Carefully install the wires not to be damaged during installation/removal of parts due to interference.
6. Be careful not to throw or drop each sensor or relay.
7. Securely connect each connector until hear a “click” sound.

Lifting Positions
1. 4-post lift
As illustrated, position the vehicle on the 4-post lift securely and block the front and rear of each tire not to move
during working.

NOTICE
During lifting, be sure to check whether vehicle is empty.
• Board-on lift connection device installed in front of vehicle should be positioned in front of sill locating
under the front door.
• Install lift connecting device on the edge of front and rear of board-on lift.

WARNING
• Be sure to use attachment during lifting to prevent the lift from contacting with body floor.
• While lifting the vehicle, widen the lift floor as far as possible to stabilize between vehicle front and rear.
When fixing the lift floor, be careful not to contact with brake tube and fuel lines.

2. Safety jack and safety stand

If lift up the vehicle with safety jack and stand, should be more careful during works.

WARNING
• Never be under the vehicle if supported with only jack. If have to be under the vehicle, be sure to use
safety block.
• Use wheel block in front and rear of every wheel.

ENGINE GENERAL INFORMATION CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 0A 25

OWNER INSPECTIONS AND SERVICES

GENERAL
WHILE OPERATING THE VEHICLE

ASSY
Horn Operation 4. Pull out the oil level indicator and look at the oil level
Blow the horn occasionally to make sure it works. Check on it.
all the button locations.

HOUSING
5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this
Brake System Operation
may cause engine damage.
Be alert for abnormal sounds, increased brake pedal
6. Push the indicator all the way back down into the

EXHAUST I N T A K E
travel or repeated puling to one side when braking. Also,
engine after taking the reading.
if the brake warning light goes on, or flashes, something
may be wrong with part of the brake system. If you check the oil level when the oil is cold, do not run
the engine first. The cold oil will not drain back to the
Exhaust System Operation pan fast enough to give a true oil level reading.
Be alert to any changes in the sound of the system or
Engine Coolant Level and Condition
the smell of the fumes. These are signs that the system
may be leaking or overheating. Have the system in- Check the coolant level in the coolant reservoir tank and
spected and repaired immediately. add coolant if necessary. Inspect the coolant. Replace

LUB
dirty or rusty coolant.
Tires, Wheels and Alignment Operation
Windshield Washer Fluid Level
Be alert to any vibration of the steering wheel or the

COOLING
seats at normal highway speeds. This may mean a wheel Check the washer fluid level in the reservoir. Add fluid if
needs to be balanced. Also, a pull right or left on a straight, necessary.
level road may show the need for a tire pressure adjust-
ment or a wheel alignment. AT LEAST TWICE A MONTH

FUEL
Steering System Operation Tire And Wheel Inspection and Pressure Check
Be alert to changes in the steering action. An inspec- Check the tire for abnormal wear or damage. Also check

CONTROL
tion is needed when the steering wheel is hard to turn or for damaged wheels. Check the tire pressure when the
has too much free play, or is unusual sounds are no- tires are cold (check the spare also, unless it is a stow-
ticed when turning or parking. away).
Headlamp Aim Maintain the recommended pressures. Refer to “Wheels

SENSOR
and Tire” is in section 4H.
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT LEAST MONTHLY
AT EACH FUEL FILL Lamp Operation
A fluid loss in any (except windshield washer) system Check the operation of the license plate lamp, the head-
may indicate a problem. Have the system inspected and lamps (including the high beams), the parking lamps, the
repaired immediately. fog lamps, the taillamp, the brake lamps, the turn signals,
the backup lamps and the hazard warning flasher.
Engine Oil Level
Check the oil level and add oil if necessary. The best Fluid Leak Check
time to check the engine oil level is when the oil is warm. Periodically inspect the surface beneath the vehicle for
1. After stopping the engine, wait a few minutes for the water, oil, fuel or other fluids, after the vehicle has been
oil to drain back to the oil pan. parked for a while. Water dripping from the air condition-
2. Pull out the oil level indicator (dip stick). ing system after use is normal. If you notice fuel leaks
3. Wipe it clean, and push the oil level indicator back or fumes, find the cause and correct it at once.
down all the way.

CHANGED BY ENGINE GENERAL INFORMATION

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
26 0A

AT LEAST TWICE A YEAR Hood Latch Operation

When opening the hood, note the operation of the sec-
Power Steering System Reservoir Level ondary latch. It should keep the hood from opening all
Check the power steering fluid level. Keep the power the way when the primary latch is released. The hood
steering fluid at the proper level. Refer to Section 4G, must close firmly.
Power Steering System.
Brake Master Cylinder Reservoir Level AT LEAST ANNUALLY
Check the fluid and keep it at the proper level. A low fluid
Lap and Shoulder Belts Condition and
level can indicate worn disc brake pads which may need
Operation
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage. Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
Weather-Strip Lubrication and the anchors.
Apply a thin film silicone grease using a clean cloth.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
EACH TIME THE OIL IS CHANGED must stay in the desired position.
Brake System Inspection Spare Tire and Jack Storage
This inspection should be done when the wheels are
Be alert to rattles in the rear of the vehicle. The spare
removed for rotation. Inspect the lines and the hoses for
tire, all the jacking equipment, and the tools must be
proper hookup, binding, leaks, cracks, chafing, etc. In-
securely stowed at all times. Oil the jack ratchet or the
spect the disc brake pads for wear. Inspect the rotors
screw mechanism after each use.
for surface condition. Inspect other brake parts, the park-
ing brake, etc., at the same time. Inspect the brakes Key Lock Service
more often if habit or conditions result in frequent braking. Lubricate the key lock cylinder.
Steering, Suspension and Front Drive Axle
Body Lubrication Service
Boot And Seal Inspection
Lubricate all the body door hinges including the hood,
Inspect the front and rear suspension and the steering
the fuel door, the rear compartment hinges and the
system for damaged, loose or missing parts, signs of
latches, the glove box and the console doors, and any
wear or lack of lubrication. Inspect the power steering
folding seat hardware.
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle Underbody Flushing
boot and seals for damage, tears or leakage. Replace
Flushing the underbody will remove any corrosive mate-
the seals if necessary.
rials used for ice and snow removal and dust control. At
Exhaust System Inspection least every spring clean the underbody. First, loosen
Inspect the complete system (including the catalytic con- the sediment packed in closed areas of the vehicle. Then
verter if equipped). Inspect the body near the exhaust flush the underbody with plain water.
system. Look for broken, damaged, missing, or out-of-
Engine Cooling System
position parts as well as open seams, holes, loose
Inspect the coolant and freeze protection fluid. If the
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep fluid is dirty or rusty, drain, flush and refill the engine
into the trunk or passenger compartment. cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
Drain the Water from Fuel Filter protection, corrosion protection and engine operating
When the water level inside water separator in fuel filter temperature. Inspect the hoses. Replace the cracked,
exceeds a certain level, water separator warning light swollen, or deteriorated hoses. Tighten the clamps.
comes on and buzzer sounds. Also, the driving force of Clean the outside of the radiator and the air conditioning
the vehicle decreases. condenser. Wash the filler cap and the neck. Pressure
If these conditions occur, immediately drain the water test the cooling system and the cap in order to help
from fuel filter & water separator. ensure proper operation.

ENGINE GENERAL INFORMATION CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 0A 27

STANDARD BOLTS SPECIFICATIONS

GENERAL
Torque (Nm / Ib-in)

ASSY
Bolt* Standard Limit
4T 7T 9T 4T 7T 9T
M3 × 0.5 0.5 Nm 0.9 Nm 1.3 Nm 0.7 Nm 1.2 Nm 17 Nm

HOUSING
(4.5 lb-in) (8 lb-in) (12 lb-in) (6.3 lb-in) (11 lb-in) (15 lb-in)
M4 × 0.7 1.2 Nm 2.0 Nm 3.0 Nm 1.6 Nm 2.6 Nm 4.0 Nm
(11 lb-in) (18 lb-in) (27 lb-in) (14 lb-in) (23 lb-in) (36 lb-in)

EXHAUST I N T A K E
M5 × 0.8 2.4 Nm 4.0 Nm 5.6 Nm 3.1 Nm 5.2 Nm 7.6 Nm
(22 lb-in) (36 lb-in) (50 lb-in) (28 lb-in) (47 lb-in) (68 lb-in)
M6 × 1.0 4.0 Nm 6.7 Nm 9.7 Nm 5.4 Nm 9.0 Nm 12.7 Nm
(36 lb-in) (60 lb-in) (87 lb-in) (49 lb-in) (81 lb-in) (114 lb-in)
M8 × 1.25 8.6 Nm 15.7 Nm 22.5 Nm 12.7 Nm 20.6 Nm 30.4 Nm
(77 lb-in) (12 lb-in) (17 lb-in) (9 lb-in) (15.2 lb-in) (22 lb-in)
M10 × 1.25 18.6 Nm 32.3 Nm 46.0 Nm 25.5 Nm 42.1 Nm 60.8 Nm

LUB
(14 lb-in) (24 lb-in) (34 lb-in) (19 lb-in) (31 lb-in) (31 lb-in)
M10 × 1.5 18.6 Nm 30.4 Nm 44.1 Nm 24.5 Nm 41.2 Nm 58.8 Nm
(14 lb-in) (22 lb-in)

COOLING
(33 lb-in) (18 lb-in) (30 lb-in) (44 lb-in)
M12 × 1.25 34.3 Nm 56.8 Nm 82.3 Nm 45.0 Nm 75.5 Nm 107.8 Nm
(25 lb-in) (42 lb-in) (61 lb-in) (33 lb-in) (56 lb-in) (80 lb-in)
M12 × 1.75 32.3 Nm 53.9 Nm 77.4 Nm 43.1 Nm 71.5 Nm 98.0 Nm

FUEL
(24 lb-in) (40 lb-in) (57 lb-in) (32 lb-in) (53 lb-in) (73 lb-in)
M14 × 1.5 54.0 Nm 89.2 Nm 127.4 Nm 71.6 Nm 117.6 Nm 166.6 Nm
(40 lb-in) (66 lb-in) (94 lb-in) (53 lb-in) (87 lb-in) (123 lb-in)

CONTROL
M16 × 1.5 81.3 Nm 107.8 Nm 196.0 Nm 107.8 Nm 186.2 Nm 264.6 Nm
(60 lb-in) (80 lb-in) (145 lb-in) (80 lb-in) (138 lb-in) (196 lb-in)
M18 × 1.5 117.6 Nm 196.0 Nm 284.2 Nm 156.8 Nm 264.6 Nm 372.4 Nm

SENSOR
(87 lb-in) (145 lb-in) (210 lb-in) (116 lb-in) (196 lb-in) (276 lb-in)
M20 × 1.5 166.6Nm 274.4 Nm 392.0 Nm 215.6 Nm 362.6 Nm 519.4 Nm
(123 lb-in) (203 lb-in) (290 lb-in) (160 lb-in) (268 lb-in) (384 lb-in)
M22 × 0.5 225.4Nm 372.4 Nm 529.2 Nm 294.0 Nm 490.0 Nm 705.6 Nm
(167 lb-in) (276 lb-in) (392 lb-in) (218 lb-in) (362 lb-in) (522 lb-in)
M24 × 1.5 284.2 Nm 480.2 Nm 686.0 Nm 382.2 Nm 637.0 Nm 921.2 Nm
(210 lb-in) (355 lb-in) (508 lb-in) (283 lb-in) (471 lb-in) (682 lb-in)
M24 × 2.0 274.4 Nm 460.6 Nm 666.4 Nm 372.4 Nm 617.4 Nm 891.8 Nm
(203 lb-in) (341 lb-in) (493 lb-in) (276 lb-in) (457 lb-in) (660 lb-in)
*Diameter X pitch in millimeters

CHANGED BY ENGINE GENERAL INFORMATION

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
28 0A

1. Metric bolt strength is embossed on the head of each 3. Determine extra proper tightening torque if tightens
bolt. The strength of bolt can be classified as 4T, 7T, with washer or packing.
8.8T, 10.9T, 11T and 12.9T in general. 4. If tightens bolts on the below materials, be sure to
2. Observe standard tightening torque during bolt determine the proper torque.
tightening works and can adjust torque to be proper 1) Aluminum alloy: Tighten to 80 % of above torque
within 15 % if necessary. Try not to over max. table.
allowable tightening torque if not required to do so.
2) Plastics: Tighten to 20 % of above torque table.

ENGINE GENERAL INFORMATION CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
ENGINE ASSEMBLY
01

TABLE OF CONTENTS
STRUCTURE AND FUNCTION DESCRIPTIONS .. 2
Major components in engine and engine compartment .............. 2
Engine structure ........................................................................ 3
Specifications and performance curve ........................................ 5

DIAGNOSTIC INFORMATION AND PROCEDURE ... 8

Oil leak diagnosis ...................................................................... 8
Compression pressure test ........................................................ 9
Cylinder pressure leakage test ................................................ 11
Tightening torque ..................................................................... 12

REMOVAL AND INSTALLATION OF ENGINE ...... 15

Removal and installation of engine assembly ........................... 15
Engine accessories ................................................................. 20

DISASSEMBLY AND REASSEMBLY ................... 24

Components and special tools ................................................. 24
Inspection before disassembly and reassembly ....................... 26
Engine accessories ................................................................. 27
Engine overhaul ....................................................................... 42
2 01

STRUCTURE AND FUNCTION DESCRIPTIONS

MAJOR COMPONENTS IN ENGINE AND ENGINE COMPARTMENT

The electronically controlled advanced D20DT engine that has high pressure fuel system has been introduced
to this vehicle. It satisfies the strict emission regulation and provides improved output and maximum torque.
modulator
ABS/ESP

Fuse box

reservoir
Washer
fluid
Brake fluid reservoir

Battery

Fuel filter & priming

pump
Power steering oil
reservoir
modulator
Vacuum
EGR valve

PWM electric
fan & fan
shroud
Vacuum

Engine oil
pump

filler cap
Oil separator

Engine
(PCV valve )
Engine oil

VGT Turbo
dipstick

charger
FFH

sensor
HFM
Air cleaner
assembly
reservoir
Coolant

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 01 3

ENGINE STRUCTURE

GENERAL
Front View Cam position sensor
Viscos clutch pulley
Tightening torque: 12 ± 1.7 Nm

ASSY
Oil dipstick gauge
Idle pulley
Oil separator EGR valve

HOUSING
(with PCV)

VGT Turbo charger

EXHAUST I N T A K E
EGR pipe
Power steering pump

Water pump pulley

Power steering pump pulley
Auto tensioner pulley
Alternator
Air conditioner compressor
Crankshaft pulley

LUB
COOLING
Auto tensioner
Oil pan

FUEL
Top View
Oil separator VGT Turbo charger

CONTROL
SENSOR
Cylinder head
Injector cover
(10 ± 1.0 Nm →
180 + 20°)
Glow plug
(15 ± 3 Nm)
Oil pipe
(40 ± 4.0 Nm) Vacuum pump (10 ± 1.0 Nm)

Fuel pressure
Common rail (25 ± 2.5 Nm)
sensor
Booster pressure sensor
Tightening torque:
Water outlet port
(10 ± 1.0 Nm)

EGR valve Oil filler

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
4 01

Right Side View EGR valve

Intake manifold

Knock sensor Booster pressure sensor

20 ± 2.6 Nm
Vacuum pump
Power steering pump
Oil filter & oil cooler
oil reservoir

Vacuum modulator for

Power steering pump EGR valve
Crank position sensor
HP pump assembly
Tightening torque: 0.8 ± 0.4 Nm
Gap: 0.7 ~ 1.5 mm

Air conditioner Flywheel

compressor

Vacuum modulator for VGT

turbocharger actuator

Engine mounting
bracket

Left Side View Oil separator (with PCV)

Oil dipstick gauge

Cylinder head
jack valve screw

EGR pipe
VGT Turbo charger
assembly
Water pump

Cylinder block assembly

Alternator

Oil pan

Engine mounting
bracket

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 01 5

SPECIFICATIONS AND PERFORMANCE CURVE

GENERAL
Specifications

ASSY
Description D20DT
Engine Type/Number of cylinders D20DT/4-cylinder
Cylinder Inner diameter (mm) 86.2

HOUSING
Stroke (mm) 85.6
Displacement (cc) 1998
Compression ratio 17.5:1

EXHAUST I N T A K E
Maximum output (ps/rpm) 141/4,000
Maximum torque (Nm/rpm) 310/1,800 ~ 2,750
Idle speed For Manual Transmission 780 ± 50 rpm
For Automatic Transmission 780 ± 50 rpm
Valve Intake Opens (BTDC) 9°
Closes (ABDC) 26°

LUB
Exhaust Opens (BBDC) 38°
Closes (ATDC) 16°

COOLING
Camshaft Type DOHC
Fuel system Fuel type Low sulfur diesel
Fuel pump type Vane pump in HP pump
Fuel supply pressure HP pump inlet port: max. 400 mbar

FUEL
HP pump outlet port (with IMV fully open):
over 1,050 bar
at every 10,000 km

CONTROL
Water separation in fuel filter
Fuel tank capacity ( ) 75
Lubrication Oil specification SAE 10W40, 5W40
system (MB Sheet 229.1, 229.3 approved oil)

SENSOR
Lubrication type Forced delivery
Oil filter type Full flow, filter element type
Oil capacity ( ) 7.5
Cooling Cooling type Water cooling type
system Cooling fan operation type Belt operated type
Thermostat Opening
(Fully Open: 100°C) temperature (°C) 85

Type WAX pellet type

Coolant capacity ( ) 11.5

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
6 01

Engine Performance Curve

Output and Torque

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 01 7

GENERAL
Oil Temperature/Pressure and Boost Pressure

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
8 01

DIAGNOSTIC INFORMATION AND PROCEDURE

OIL LEAK DIAGNOSIS Black Light and Dye Method

Most fluid oil leaks are easily located and repaired by A dye and light kit is available for finding leaks, Refer to
visually finding the leak and replacing or repairing the the manufacturer’s directions when using the kit.
necessary parts. On some occasions a fluid leak may 1. Pour the specified amount of dye into the engine oil fill
be difficult to locate or repair. The following procedures tube.
may help you in locating and repairing most leaks.
2. Operate the vehicle normal operating conditions as
directed in the kit.
Finding the Leak 3. Direct the light toward the suspected area. The dyed
1. Identify the fluid. Determine whether it is engine oil, fluid will appear as a yellow path leading to the source.
automatic transmission fluid, power steering fluid,
etc. Repairing the Leak
2. Identify where the fluid is leaking from.
Once the origin of the leak has been pinpointed and traced
1) After running the vehicle at normal operating back to its source, the cause of the leak must be deter-
temperature, park the vehicle over a large sheet mined in order for it to be repaired properly. If a gasket is
of paper. replaced, but the sealing flange is bent, the new gasket
2) Wait a few minutes. will not repair the leak. The bent flange must be repaired
3) You should be able to find the approximate also. Before attempting to repair a leak, check for the
location of the leak by the drippings on the paper. following conditions and correct them as they may cause
a leak.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas Gaskets
that are hard to reach.
1. The fluid level/pressure is too high.
4. If the leak still cannot be found, it may be necessary
2. The crankcase ventilation system is malfunctioning.
to clean the suspected area with a degreaser,
steam or spray solvent. 3. The fasteners are tightened improperly or the threads
are dirty or damaged.
1) Clean the area well.
4. The flanges or the sealing surface is warped.
2) Dry the area.
5. There are scratches, burrs or other damage to the
3) Operate the vehicle for several miles at normal
sealing surface.
operating temperature and varying speeds.
6. The gasket is damaged or worn.
4) After operating the vehicle, visually check the
suspected component. 7. There is cracking or porosity of the component.

5) If you still cannot locate the leak, try using the 8. An improper seal was used (where applicable).
powder or black light and dye method.
Seals
1. The fluid level/pressure is too high.
Powder Method 2. The crankcase ventilation system is malfunctioning.
1. Clean the suspected area. 3. The seal bore is damaged (scratched, burred or nicked).
2. Apply an aerosol-type powder (such as foot powder) 4. The seal is damaged or worn.
to the suspected area.
5. Improper installation is evident.
3. Operate the vehicle under normal operating
6. There are cracks in the components.
conditoins.
7. The shaft surface is scratched, nicked or damaged.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the white 8. A loose or worn bearing is causing excess seal wear.
powder surface to the source.

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 01 9

COMPRESSION PRESSURE TEST

GENERAL
The compression pressure test is to check the conditions of internal components (piston, piston ring, intake and
exhaust vale, cylinder head gasket). This test provides current engine operating status.

ASSY
NOTICE
• Before cranking the engine, make sure that the test wiring, tools and persons are keeping away from moving
components of engine (e.g., belt and cooling fan).

HOUSING
• Park the vehicle on the level ground and apply the parking brake.
• Do not allow anybody to be in front of the vehicle.

EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR
Specifications
Compression ratio 18 : 1
Test temperature at normal operating temperature (80°C)
Compression pressure Normal value 32 bar
Minimum value 18 bar
Permissible pressure difference between individual cylinders Max. 3 bar

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
10 01

Measuring Procedure

NOTICE
• Disconnect the fuel rail pressure sensor connector to cut off the fuel injection.
• Discharge the combustion residues in the cylinders before testing the compression pressure.
• Apply the parking brake before cranking the engine.

1. Warm the engine up to normal operating temperature

(80°C).
2. Disconnect the fuel rail pressure sensor connector
to cut off the fuel injection.
3. Place the diagram sheet to compression pressure
tester.

4. Remove the glow plugs and install the compression

pressure tester into the plug hole.

Tightening torque (Tester) 15 Nm

5. Crank the engine for approx. 10 seconds by using

the start motor.
6. Record the test result and measure the compression
pressure of other cylinders with same manner.
7. If the measured value is not within the specifications,
perform the cylinder pressure leakage test.

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 01 11

CYLINDER PRESSURE LEAKAGE TEST

GENERAL
If the measured value of the compression pressure test is
not within the specifications, perform the cylinder pres-
sure leakage test.

ASSY
HOUSING
EXHAUST I N T A K E
LUB
Permissible Pressure Leakage
Test temperature at normal operating temperature (80°C)

COOLING
At whole engine Max. 25 %
At valve and cylinder head gasket Max. 10 %
At piston ring Max. 20 %

FUEL
NOTICE
• Perform the pressure leakage test in order (1 - 2 - 3 - 4)

CONTROL
• Do not test the cylinder pressure leakage with wet type test procedure. (do not inject the engine oil into the
combustion chamber)

SENSOR

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
12 01

TIGHTENING TORQUE
NO. Name Size Quantity Tightening Torque (Nm)
55 ± 5
1 Main bearing cap M11 x 67 10
120° ± 10°
40 ± 5
2 Connecting rod cap M9 x 51 8
90° ± 10°
3 Rear cover M6 x 20 6 10 ± 1
4 Oil pump M8 x 35SOC 3 25 ± 2.5
M6 x 40 6 10 ± 1
5 T.G.C.C M6 x 60 3 10 ± 1
M6 x 70 2 10 ± 1
45 ± 5
6 Flywheel M10 x 22 8
90° ± 10°
200
7 Crankshaft hub M20 x 85 1
180° ± 10°
M6 x 20 20 10 ± 1
M6 x 35 3 10 ± 1
8 Oil pan
M6 x 85 3 10 ± 1
M8 x 40 4 25 ± 2.5
9 High pressure pump mounting bolt M8 x 55 3 25 ± 2.5
10 High pressure pump main nut (intershaft) M14 x 1.5 1 65 ± 5
M8 x 25 2
25 ± 2.5
M8 x 50 2
11 Cylinder head
M10 x 158 1 85 ± 5
M10 x 177 9 270° + 10°
12 Camshaft sprocket (Intake) 25 ± 2.5
M11 x 40 1
13 Camshaft sprocket (Exhaust) 90° ± 10°
14 Chain tensioner M24 1 65 ± 5
M12 x 90 (UP) 1 82 ± 6
15 Auto tensioner
M8 x 45 (LOWER) 1 32 ± 3
16 Water pump assembly M6 x 50 7 10 ± 1
17 Water pump pulley M6 x 10 4 10 ± 1
18 Hot water inlet pipe assembly M6 x 12 2 10 ± 1
M8 x 80 1 25 ± 2.5
19 Alternator bracket M8 x 34 2 25 ± 2.5
M8 x 30 2 25 ± 2.5
M10 x 90 1 46 ± 4.6
20 Alternator
M10 x 116 1 46 ± 4.6

ENGINE ASSEMBLY CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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Tightening Torque (Nm)

GENERAL
NO. Name Size Quantity
Air conditioner compressor M8 x 25 1 25 ± 2.5
20
bracket assembly M8 x 60 3 25 ± 2.5
Air conditioner compressor M6 x 16 1 10 ± 1.0

ASSY
22
sub bracket assembly M8 x 20 1 25 ± 2.5
M8 x 50 5 25 ± 2.5
23 Intake manifold

HOUSING
M8 x 133 5 25 ± 2.5
M6 x 16 2 25 ± 2.5
24 Acoustic cover bracket
M8 x 105 1 25 ± 2.5

EXHAUST I N T A K E
25 Knock sensor M8 x 28 1 20 ± 2.6
26 Camshaft position sensor M8 x 14 1 12 ± 1.7
27 Booster pressure sensor M6 x 20 2 10 ± 1.0
M8 x 46 8 15 ± 1.5
28 Exhaust manifold stud bolt
M8 x 35 2 15 ± 1.5
29 Exhauster manifold nut M8 8 40 ± 4.0

LUB
30 Turbo charger assembly M8 3 25 ± 2.5
31 Turbocharger hollow bolt M10 x 1.0 1 18 ± 1.8
32 Turbocharger oil feed pipe M16 (Cylinder block side) 1 25 ± 2.5

COOLING
33 Turbocharger support bar (nut) M8 1 23 ± 2.3
34 Turbocharger support bar (bolt) M8 x 20 1 25 ± 2.5
M6 x 16 (T/C side) 2 10 ± 1.0

FUEL
35 Turbocharger return pipe
M6 x 16 (Cylinder block side) 2 10 ± 1.0
36 EGR valve assembly M6 x 25 4 10 ± 1.0

CONTROL
37 EGR-LH pipe nut M8 2 35 ± 3.5
38 EGR-RH pipe nut M6 x 16 2 10 ± 1.0
39 EGR center bolt M6 x 16 4 10 ± 1.0

SENSOR
M8 x 25 2 25 ± 2.5
40 EGR center pipe
M8 x 30 2 25 ± 2.5
41 Glow plug M5 5 15 ± 3.0
M6 x 20 3 10 ± 1.0
42 Vacuum pump
M6 x 25 5 10 ± 1.0
M6 x 55 1 10 ± 1.0
43 Cooling fan bracket assembly
M6 x 85 3 10 ± 1.0
44 Cylinder head cover M6 x 35 18 10 ± 1.0
45 Vacuum modulator M6 x 16 4 10 ± 1.0
46 Oil dipstick tube M6 x 16 1 10 ± 1.0
M8 x 35 1 25 ± 2.5
47 Oil filter assembly M8 x 55 2 25 ± 2.5
M8 x 125 1 25 ± 2.5

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
14 01

NO. Name Size Quantity Tightening Torque (Nm)

48 Fuel rail assembly M8 x 35 2 25 ± 2.5
10 ± 1.0
49 Injector M6 x 60 4
180° + 20°
50 Fuel pipe clip (H-C) M14 2 40 ± 4.0
51 Fuel pipe clip (C-I) M14 8 40 ± 4.0
M6 x 14 1 0.8 ± 0.4
52 Crankshaft position sensor
GAP - 0.7 ± 1.5 mm
53 Power steering pump M8 x 100 2 25 ± 2.5
54 Head screw plug - 1 25 ± 2.5
55 Cam shaft cap bolt M8 x 60 20 25 ± 2.5
56 Piston topping - - 0.765 ~ 1.055 mm
57 Connecting rod end play - - 0.500 ~ 1.500 mm
58 Cam shaft end play - - 0.100 ~ 0.350 mm
59 Crank shaft end play - - 0.100 ~ 0.254 mm

ENGINE ASSEMBLY CHANGED BY

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 01 15

REMOVAL AND INSTALLATION OF ENGINE

GENERAL
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

ASSY
Removal

HOUSING
Preceding Work

1. Disconnect the negative

battery cable.

EXHAUST I N T A K E
2. Drain the engine coolant.

LUB
COOLING
FUEL
CONTROL
SENSOR
Summary of Engine Removal

Remove the engine accessories, front

bumper and radiator. Unscrew the
engine mounting bolts (17 mm) at
both sides and remove the engine
assembly.

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
16 01

Removal and Installation

Preceding Work

1. Disconnect the negative battery cable and remove the

skid plate under the engine compartment.

Installation Notice
Tightening torque 12 ± 1.2 Nm

2. Drain the engine coolant.

NOTICE
• Use only the designated container to collect the
coolant. Store it in a safe place and observe the regu-
lation when disposing.
• Use only Ssangyong genuine engine coolant when
refilling.

3. Remove the transmission and transfer case assembly.

Be careful not to spill the oil from the oil lines when
disconnecting them in the vehicle with automatic
transmission.

ENGINE ASSEMBLY CHANGED BY

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 01 17

4. Remove the engine hood assembly (refer to “Body”

GENERAL
section).

ASSY
HOUSING
EXHAUST I N T A K E
5. Remove the coolant reservoir (A), coolant return hose (B) and air cleaner front air duct (C).

A. Coolant Reservoir

Mounting

LUB
bolts

COOLING
Clamp
Supply
hoses

FUEL
Mounting bolts

Unscrew the mounting bolts (10 mm), dis-

connect the return/supply hoses, and re-

CONTROL
move the coolant reservoir.

SENSOR
B. Return Hose and Pipe C. Air Cleaner Front Duct

Return hose and pipe

Radiator upper hose

Release the clamps on the reservoir and Unscrew the mounting bolts (10 mm), re-
radiator and remove the return hose and pipe. lease the hose clamps, and remove the air
cleaner front duct.

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
18 01

6. Remove the air cleaner intake hose and HFM sensor.

HFM sensor

Hose (LH)
7. Remove the left intercooler hose and the lower hose of
the radiator. Remove the right intercooler hose and the
upper hose of the radiator.

Intercooler hose

Radiator lower hose

Hose (RH)

Intercooler hose

Radiator upper hose

ENGINE ASSEMBLY CHANGED BY

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 01 19

MEMO

GENERAL
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

ASSY
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

HOUSING
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

EXHAUST I N T A K E
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

LUB
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

COOLING
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

FUEL
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

CONTROL
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

SENSOR
.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

.................................................................................................................................................................................................................................................................................................................................................................................................................................................................

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CHANGED BY ENGINE ASSEMBLY

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20 01

ENGINE ACCESSORIES
Remove/disconnect the accessories as below (no specific sequence):

Engine Main Wiring Connector Booster Vacuum Hose

Heater Hose and Pipe

Main wiring

Alternator Wiring Harness

Battery Cable and Battery Assembly

Ground

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 21

GENERAL
ASSY
Fuel Filter Hose Preheat Control Unit Connector

HOUSING
EXHAUST I N T A K E
A/C Compressor Connector

LUB
and Inlet/Outlet Pipes

COOLING
Vacuum hose
Preheat relay

FUEL
Fuel pump
Tightening torque: 16 ~ 23 Nm

CONTROL
Power steering pump

SENSOR
Negative Cable to Engine Power Steering Pump
Pipes and Hose

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
22 01

Remove two engine mounting bolts (LH/RH) and remove the engine assembly using the engine jack.

Rear bracket for engine removal Front bracket for engine removal

Engine
mounting
Engine
mounting

LH mounting (lower side of VGT) RH mounting (lower side of HP pump)

ENGINE ASSEMBLY CHANGED BY

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 01 23

GENERAL
Mounting Location in Underbody

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
24 01

DISASSEMBLY AND REASSEMBLY

COMPONENTS AND SPECIAL TOOLS

Injector Puller Glow Plug Wrench Sealing Caps

Fuel Pipe Wrench
Y99220072B Y99220132B 665 995 5844

Injector Copper Washer Puller

Y99220022B

Valve Remover/Installer Pulley Lock/Wrench Engine Lock

Y99220082B Y99220052B 602 589 00 40 00

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 25

GENERAL
ASSY
Glow Plug Socket

HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

Removal/Installation Device Removal/Installation Socket

for HP Pump for High Pressure Pipe Head Bolt Wrench

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
26 01

INSPECTION BEFORE DISASSEM-

BLY AND REASSEMBLY
Preparations and Preceding Works
1. Remove the cylinder block drain plug and seal and
completely drain the residual coolant from the cylinder
block.
Installation Notice
Tightening torque 30 Nm

Replace the seal with new one once removed.

2. When the fan belt is installed, gently pump the belt

shock absorber mounting bolt (M19) 3 times.
3. Take off the fan belt while pushing the mounting bolt
(M19).

4. Loosen the oil drain plug and completely drain the

engine oil.
Installation Notice
Tightening torque 25 ± 2.5 Nm

ENGINE ASSEMBLY CHANGED BY

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 01 27

ENGINE ACCESSORIES

GENERAL
PCV valve and oil
separator

ASSY
HOUSING
Turbo charger
EGR pipe
(LH, Center, RH)

Cooling fan clutch

EXHAUST I N T A K E
Auto tensioner

LUB
COOLING
Alternator

Fuel return hose

FUEL
EGR valve

Cable and connector

CONTROL
Oil filter assembly
Power steering
pump

SENSOR
Air conditioner
compressor

Start motor

Mounting bracket

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
28 01

Cautions When Installing the Engine

1. Connection of vacuum hose

The vacuum hose from the vacuum modula-

tor for turbocharger actuator control should
be routed under the fuel return hose and the
engine main wiring.

Be careful with
the intereference

The vacuum hose for

the EGR valve should
be routed over the
engine main wiring.

2. Tightening torque of oil pipes on VGT

Turbocharger assembly

25 ± 2.5 Nm Turbocharger actuator

Oil supply tube Hollow bolt

25 ± 2.5 Nm 18 ± 1.8 Nm

Support bar

Oil return tube

Nut 23 ± 2.3 Nm

Upper 10 ± 1.0 Nm
Bolt 25 ± 2.5 Nm

Lower 10 ± 1.0 Nm

ENGINE ASSEMBLY CHANGED BY

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 01 29

GENERAL
3. Vacuum modulator

ASSY
Tightening torque: 10 ± 1.0 Nm

HOUSING
EXHAUST I N T A K E
VGT turbocharger VGT vacuum outlet hose
vacuum modulator
connector
Gray

LUB
EGR valve EGR vacuum outlet hose
vacuum modula-
tor connector

COOLING
Black

FUEL
CONTROL
SENSOR

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
30 01

Sealant for Engine

Applied Locations

Timing Gear Case Cover Vacuum Pump

Oil Pan Idle Pulley Bracket

1. Sealant specification:
- DB 2210 (Drei Bond)
- Part number: 661 989 56 A0
- Characteristic: It is hardened twice faster than Loctite 5900.
2. Precautions:
- Never use Loctite 5900 on DI engine.
- Be careful not to clog the oil hole with sealant when installing the vacuum pump.

ENGINE ASSEMBLY CHANGED BY

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 01 31

GENERAL
The engine accessories can be removed without any specific order. In general, remove the components from
top to bottom. However, be careful not to splash the lubricants to engine and body when disassembly.
Especially, avoid getting into other components.

ASSY
Removal and Installation Order of Major Accessories
1) Camshaft Position Sensor

HOUSING
1. Vacuum Modulator
2) Crankshaft Position Sensor
3) Injector Fuel Line Connector
4) Glow Plug Connector

EXHAUST I N T A K E
2. Engine Cables and Connectors 5) Fuel Return Hose
6) High/Low Pressure Hoses in HP Pump
7) Ground Cables
8) Fuel Pressure Sensor Connector
3. Fuel Hoses 9) Booster Pressure Sensor Connector
10) Knock Sensor Connector

LUB
11) Coolant Temperature Sensor Connector
12) HP Pump: Fuel Temperature Sensor (Green)
3-1. EGR Valve Assembly IMV (Brown)

COOLING
FUEL
4. Oil Filter Assembly

CONTROL
4-1. Belt Tensioning Assembly

SENSOR
5. Power Steering Pump Assembly

6. Air Conditioner Compressor Assembly

7. PCV Valve Assembly + Oil Dipstick Tube

8. Turbo Charger Alternator Assembly

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
32 01

1. Remove the fuel pipes.

1) Remove the fuel supply pipes between each
cylinder and common rail with a special tool.

Installation Notice
Tightening torque 40 ± 4.0 Nm

NOTICE
• Plug the openings of injector nozzle and common
rail with sealing caps after removed the fuel pipes.

NOTICE
• Replace the pipes with new ones. Be careful not to
be mixed the fuel pipes because the pipe appear-
ance of D27DT (#1 and #3 cylinders and #2 and #4)
are same each other.

2) Remove the high fuel pressure pipe mounting bolts

with a special tool.
• High fuel pressure supply pipe at common rail side

Installation Notice
Tightening torque 40 ± 4 Nm

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 33

3) High fuel pressure supply pipe at HP pump side

GENERAL
Installation Notice
Tightening torque 40 ± 4.0 Nm

ASSY
HOUSING
EXHAUST I N T A K E
4) Unscrew the bracket mounting bolts and remove
the high fuel pressure supply pipes.

NOTE
• Special tool: Fuel pipe remover and installer

LUB
COOLING
2. Disconnect the vacuum hoses and module cables from

FUEL
Turbo charger booster
the vacuum modulator. vacuum modulator

CONTROL
NOTICE
• Put the installation marks on the modulator hoses To turbo
and connectors. charger
From vacuum
booster
pump

SENSOR
EGR booster
vacuum modulator

1) Remove the vacuum modulator bracket.

(Upper: 10 M x 2, Lower: 10M x 2)

Installation Notice
Upper bolt 25 ± 2.5 Nm
Lower bolt 25 ± 2.5 Nm

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
34 01

3. Disconnect the wiring harnesses and connectors from the engine.

Fuel Return Hose Injector Fuel Line Glow Plug Connector

Connector

Camshaft Position Crankshaft Position

Sensor Sensor

HP Pump Connector Oil Pressure Switch

Fuel temperature
Sensor

IMV

Coolant Temperature Fuel Pressure Sensor Booster Pressure

Knock Sensor Connector Sensor Connector Connector Sensor Connector

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 35

1) Remove the cable assembly from the engine.

GENERAL
IMPORTANT
• If possible, remove the cables after removing the

ASSY
fuel pipes. It makes the operation easier and pro-
tect the cables and connectors.

HOUSING
IMPORTANT
• Remove the cable screws and ground cable, and
then remove the engine cable assembly.

EXHAUST I N T A K E
NOTICE
• Be careful not to damage the HP pump connecting
pipe (venturi) while removing the fuel hose from the
HP pump.

4. Disconnect the high and low fuel pressure hoses from

the HP pump.

LUB
NOTICE
• Be careful not to damage the hose connections.

COOLING
• Plug the openings in HP pump immediately after
disconnecting the hoses.

FUEL
CONTROL
SENSOR
5. Remove the EGR valve and EGR valve pipe.
1) Disconnect the vacuum hose from the EGR valve.
2) Unscrew the EGR valve bolts and EGR #1 pipe
connecting bolts and remove the EGR valve and steel
gasket.
Installation Notice D20DT
EGR valve bolt 10 ± 1.0 Nm, M6
EGR valve and
10 ± 1.0 Nm, M6
center pipe bolt

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
36 01

3) Remove the EGR valve #1 pipe.

Installation Notice

Center pipe mounting bolt 25 ± 2.5 Nm

Center pipe and #1 pipe
35 ± 3.5 Nm
bolt and nut

• The EGR #2 pipe should be replaced with new one.

4) Unscrew the EGR valve #3 pipe (2) mounting bolts

and remove the pipe from the exhaust manifold.

Installation Notice
Tightening torque Nut 35 ± 3.5 Nm
Bolt 10 ± 1.0 Nm 2

• The EGR #3 pipe should be replaced with new

one.
• Make sure that the convex surface of new steel
gasket is facing to the bolts.

6. Remove the oil filter assembly.

1) Remove the oil cooler hose.

2) Remove the oil filter assembly mounting bolts.

NOTICE
• Be careful not to flow out the residual oil from the
engine. If flown out, immediately wipe it out.

ENGINE ASSEMBLY CHANGED BY

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 01 37

3) Remove the oil filter assembly from the cylinder

GENERAL
block.

Installation Notice
• Replace the oil filter gasket with new one.

ASSY
Tightening torque 25 ± 2.5 Nm

HOUSING
EXHAUST I N T A K E
7. Remove the belt tensioning device.
1) Remove the shock absorber lower mounting bolt.

Installation Notice
Tightening torque 32 ± 3 Nm

LUB
COOLING
2) Remove the shock absorber upper mounting bolt.

FUEL
Installation Notice
Tightening torque 82 ± 6 Nm

3) Remove the belt tensioning device. CONTROL

SENSOR

NOTICE
• To prevent the oil leaks, store the removed shock
absorber assembly with standing up.
• For air bleeding, pump the shock absorber around
3 times after installation.
• Be careful not to damage the rubber parts of the
shock absorber when removing.
• To prevent the oil leaks, remove the bolts from bot-
tom to top section. On the contrary, when installing,
tighten the bolts from top to bottom section.

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
38 01

8. Remove the power steering pump assembly.

1) Remove the power steering pump mounting bolts.

Installation Notice
Tightening torque 25 ± 2.5 Nm

• Be careful not to flow out the oil.

2) Remove the power steering pump assembly from

the engine.

NOTICE
• To prevent the oil leaks, store the removed power
steering pump assembly with standing up.

9. Remove the air conditioner compressor assembly.

1) Unscrew the bolts and remove the air conditioner
compressor assembly.

Installation Notice
Tightening torque 25 ± 2.5 Nm

2) Unscrew the bolts and remove the air conditioner

mounting bracket.

Installation Notice
Front bolt 25 ± 2.5 Nm
Side bolt 25 ± 2.5 Nm

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 39

10. Remove the PCV valve assembly.

GENERAL
1) Remove the PCV valve hose.

ASSY
HOUSING
EXHAUST I N T A K E
2) Remove the PCV valve hose connected to the
engine oil hose.

LUB
COOLING
3) Unscrew the PCV valve mounting bolts and

FUEL
remove the PCV valve assembly.

Installation Notice

CONTROL
Tightening torque 10 ± 1.0 Nm

11. Remove the oil dipstick tube assembly. SENSOR

Unscrew the bracket bolts and remove the dipstick

tube with O-ring.

NOTICE
• Insert new O-ring into the oil dipstick tube before
installation.

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
40 01

Installation Notice
Tightening torque 10 ± 1.0 Nm

12. Remove the turbo charger assembly.

1) Unscrew the bolts and remove the oil supply pipe.

Installation Notice

Upper bolt (M19) 25 ± 2.5 Nm

Lower bolt (M17) 20 ± 2.0 Nm

2) Unscrew the bolts and remove the oil return pipe.

Installation Notice
• Make sure to install the gasket with correct
direction.

Tightening torque 10 ± 1.0 Nm

3) Unscrew the turbo charger mounting bracket

bolts.

Installation Notice
Tightening torque 25 ± 2.5 Nm

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 41

4) Unscrew the turbo charger mounting bolts to

GENERAL
exhaust manifold.

Installation Notice
Tightening torque 25 ± 2.5 Nm

ASSY
NOTICE

HOUSING
• Use only 12 1/2 wrench.

EXHAUST I N T A K E
5) Remove the turbo charger assembly.

LUB
COOLING
13. Remove the alternator assembly.

FUEL
1) Unscrew the bolts and remove the alternator.

CONTROL
NOTICE
• Alternator Capacity: 140 A

Installation Notice

SENSOR
Tightening torque 46 ± 4.6 Nm

2) Remove the alternator mounting bracket.

Installation Notice
M13 bolt 25 ± 2.5 Nm
Torx 6 bolt 25 ± 2.5 Nm

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
42 01

ENGINE OVERHAUL
1. Unscrew the injector nozzle holder bolts (12-sided)
and remove the injector bracket.

Installation Notice
9 ± 1.0 Nm,
Tightening torque
190° + 10°

2. Remove the injectors with a injector extractor (special

tool).

NOTICE
• Be careful not to take off the sealing caps on the
injectors and fuel system.
• Replace the copper washers with new ones when
installing.

3. If the copper washer is in injector hole, remove it with

a special tool as shown in the figure.

4. Remove the glow plugs with a special tool.

Installation Notice
Tightening torque 15 ~ 18 Nm

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 43

5. Unscrew the Torx bolts and remove the common rail

GENERAL
from the engine.

Installation Notice
Tightening torque 25 ± 2.5 Nm

ASSY
NOTICE

HOUSING
• Plug the openings with sealing cap.

EXHAUST I N T A K E
6. Remove the booster sensor from the engine.

Installation Notice
Tightening torque 10 ± 1.0 Nm

LUB
COOLING
7. Unscrew the bolt and remove the camshaft position

FUEL
sensor.

Installation Notice

CONTROL
Tightening torque 12 ± 2 Nm

Apply Loctite on the thread before installation.

8. Unscrew the bolts and remove the cooling fan pulley SENSOR
while holding it with a special tool.

Installation Notice
Tightening torque 10 ± 1.0 Nm

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
44 01

9. Remove the cooling fan belt idle pulley while holding

it with a special tool.

Installation Notice
Tightening torque 10 ± 1.0 Nm

10. Unscrew the bolts and remove the cooling fan

bracket assembly (timing chain cover).

Installation Notice
Tightening torque 10 ± 1.0 Nm

11. Unscrew the bolts and remove the cylinder head

cover.

Installation Notice
Tightening torque 10 ± 1.0 Nm

12. Turn over the engine and remove the oil pan.

Installation Notice
Tightening torque Nm
M6 x 20: 24 EA 10 ± 1.0
M6 x 35: 3 EA 10 ± 1.0
M6 x 85: 3 EA 10 ± 1.0
M8 x 40: 4 EA 25 ± 2.5

ENGINE ASSEMBLY CHANGED BY

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AFFECTED VIN
 01 45

GENERAL
NOTICE
• Remove the oil seal residues from the oil pan and
apply the liquid gasket on the parting surface.

ASSY
HOUSING
EXHAUST I N T A K E
13. Unscrew the nuts and remove the exhaust manifold.

Installation Notice
Tightening torque 40 ± 4.0 Nm

NOTICE

LUB
• The exhaust manifold gasket is removed along with
the exhaust manifold. Mark the installation direc-
tion to prevent wrong installation. Otherwise, it may
cause a sealing trouble.

COOLING
14. Unscrew the bolts and remove the thermostat.

FUEL
Installation Notice
Tightening torque 10 ± 1.0 Nm

CONTROL
• Be careful not to flow out the residual coolant.

15. Unscrew the bolts and remove the water pump. SENSOR

Installation Notice
Tightening torque 10 ± 1.0 Nm

CHANGED BY ENGINE ASSEMBLY

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
46 01

16. Unscrew the bolts and remove the water pump

housing.

Installation Notice
Tightening torque 10 ± 1.0 Nm

• Be careful not to flow out the residual coolant.

17. Unscrew the bolts and remove the coolant inlet port
from the intake manifold.

Installation Notice
Tightening torque 25 ± 2.5 Nm

• Be careful not to get the coolant into the intake

manifold and engine.

18. Unscrew the bolts and remove the intake manifold

assembly.

Installation Notice
Tightening torque 25 ± 2.5 Nm

NOTICE
• Replace the gasket with new one once removed.

19. Remove the vacuum pump from the cylinder head.

Installation Notice
Tightening torque 10 ± 1.0 Nm

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20. Install the engine lock (special tool) onto the flywheel

GENERAL
ring gear so that the engine will not rotate.

ASSY
HOUSING
EXHAUST I N T A K E
21. Remove the chain tensioner.
Preceding Works: removal of EGR pipe and oil
dipstick tube

Installation Notice
Tightening torque 65 ± 5.0 Nm

LUB
COOLING
22. Pull out the lock pin and remove the upper chain

FUEL
guide bracket.

23. Unscrew the bolt and remove the intake camshaft CONTROL
SENSOR
sprocket.

Installation Notice
25 ± 2.5 Nm,
Tightening torque
90° ± 10°

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24. Unscrew the bolt and remove the exhaust camshaft

sprocket.

Installation Notice
25 ± 2.5 Nm,
Tightening torque
90° ± 10°

25. Remove the camshaft bearing cap bolts so that the Exhaust
tightening force can be relieved evenly.
• Intake: #6, #8, #10
• Exhaust: #1, #3, #5
However, there is no specific removal sequence.

Intake

• Intake: #7, #9
• Exhaust: #2, #4
Do not remove the bolts at a time completely.
Remove them step by step evenly or camshaft can
be seriously damaged.

Installation Notice

Tightening torque 25 ± 2.5 Nm

26. Remove the intake and exhaust camshafts from the

cylinder head.

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27. Remove the finger follower and the HLA device.

GENERAL
NOTICE
• Avoid contact with hot metal parts when removing

ASSY
the HLA device immediately after stopping the
engine.
• Be careful not to be contaminated by foreign
materials.

HOUSING
• To prevent the oil leaks, store the removed finger
follower and HLA device with standing up.
• If the HLA can be easily pressed in by hand, it indi-
cates the oil inside of HLA has been flown out. In

EXHAUST I N T A K E
this case, replace it with new one.

28. Pull out the pin and remove the timing chain guide
from the engine.

LUB
COOLING
29. Remove the cylinder head bolts according to the

FUEL
numerical sequence.

Installation Notice

CONTROL
Tightening torque Nm
M8 x 25: 2 EA 25 ± 2.5
M8 x 50: 2 EA 25 ± 2.5

SENSOR
M12 x 177: 11 EA
85 ± 5 Nm,
M12 x 158: 1 EA
3 x 90° + 10°
(Vacuum pump side)

30. Measure the length of cylinder head bolts.

If the maximum length is exceeded by 2 mm, replace
the cylinder head bolt.

Length when new Maximum Limit

177 mm 179 mm
158 mm 160 mm

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31. Remove the cylinder head.

NOTICE
• Inspect the cylinder head surface.
• Store the removed injectors and glow plugs so that
they will not be damaged.

32. Measure the piston protrusion from the parting

surface.
Specified Value: 0.765 ~ 1.055 mm

33. Remove the cylinder head gasket.

Installation Notice
• Replace the cylinder head gasket with new
one. Make sure to place the “TOP” mark
upward.
1. Put the steel gasket on the cylinder block and
position the cylinder head.
2. Tighten the cylinder head bolts to specified
torque and torque angle.

Step 1 20 ± 2.0 Nm
Tightening torque Step 2 85 ± 5.0 Nm
Step 3 90 ± (3 times) + 10°

• Apply the oil on the bolt thread when installing.

• Always insert new washer first.
• The bolts (12) at vacuum pump side are shorter
than others.

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34. Turn over the engine and remove the baffle plate.

GENERAL
Installation Notice
Tightening torque 10 ± 1.0 Nm

ASSY
HOUSING
EXHAUST I N T A K E
35. Unscrew the bolts and remove the oil strainer
assembly.

Installation Notice
Tightening torque 25 ± 2.5 Nm

LUB
COOLING
36. Remove the piston assembly from the cylinder block.

FUEL
1) Unscrew the bearing cap bolts.

Installation Notice

CONTROL
Step 1 55 ± 5.0 Nm
Step 2 90° + 10°

Tighten the bolts from #1 cap.

SENSOR
NOTICE
• Align the oil grooves in bearing cap and connect-
ing rod.

2) Remove the bearing caps and lower bearing

shells.

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3) Remove the piston assembly through the cylinder.

NOTICE
• Do not mix up upper and lower crankshaft bearing
shells.

4) Remove the snap ring piston pin from the piston.

5) Disassemble the piston and connecting rod.
6) Remove the piston rings from the piston.

NOTICE
• Replace the piston ring, bearing and snap ring with
new ones.

37. Lock the flywheel and remove the center bolt and
crankshaft pulley.

Installation Notice
200 ± 20 Nm,
Tightening torque
180° + 10°

38. Remove the timing chain cover assembly.

1) Remove the cover bolts.

Installation Notice
Tightening torque 10 ± 1.0 Nm

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2) Hold the timing chain and remove the timing chain

GENERAL
cover by tapping it with a rubber hammer and a
screwdriver.

ASSY
NOTICE
• Apply the sealant on the parting surface.

HOUSING
EXHAUST I N T A K E
39. Remove the timing chain guide rail and timing chain.

LUB
COOLING
40. Remove the HP pump bolts and the HP pump bracket

FUEL
bolts.

1) Remove the HP pump assembly. CONTROL

SENSOR

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41. Remove the crankshaft sprocket with a special tool.

42. Remove the flywheel and the crankshaft strainer.

Installation Notice
45 ± 5.0 Nm,
Tightening torque
90° + 10°

43. Unscrew the bolts and remove the crankshaft bearing

caps.

Installation Notice
55 ± 5.0 Nm,
Tightening torque
90° + 10°

NOTICE
• Remove the bearing cap bolts from inside to out-
side with a pair.
• Do not mix up the crankshaft bearing caps and
shells.

NOTE
• Install in the reverse order of removal.
• Tighten the fasteners with the specified tightening
torques.
• Replace the gaskets and bearings with new ones.
• Make sure to install the gaskets in correct
direction.

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02

TABLE OF CONTENTS
CYLINDER HEAD/CYLINDER BLOCK .................. 2
Cylinder head ............................................................................. 2
Camshaft assembly ................................................................. 14
Timing chain assembly ............................................................ 23
Cylinder block .......................................................................... 27

CRANKSHAFT ...................................................... 30
Arrangement of thrust washers and bearings ........................... 31
Torsional vibration damper ........................................................ 36
Disassembly and reassembly .................................................. 37

FLYWHEEL ........................................................... 40
Dual mass flywheel (DMF, manual transmission equipped
vehicle) ..................................................................................... 40

PISTON AND CONNECTING ROD ....................... 42

Piston ring ............................................................................... 43
Cylinder inner diameter and piston size ................................... 44
Disassembly and reassembly .................................................. 45

HIGH PRESSURE PUMP (HPP) ........................... 49

Components locator ................................................................. 49
Disassembly and reassembly .................................................. 52
2 02

CYLINDER HEAD/CYLINDER BLOCK

CYLINDER HEAD

Cylinder head bolt

Oil Return Check Valve

System Characteristics
1. 4-valve DOHC valve mechanism
2. Swirl and tangential port
3. 4-bolt type cylinder head bolt
4. Water jacket integrated casting
5. Integrated chain housing and cylinder head
Intake manifold Exhaust manifold
6. Oil gallery: drilled and sealing with cap and screw plug

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Cylinder Head Pressure Leakage Test

GENERAL
Preceding Works:
1. Removal of cylinders
2. Removal of intake and exhaust manifold

ASSY
3. Removal of valves

Test Procedures

HOUSING
1. Place the pressure plate on a flat-bed work bench.

EXHAUST I N T A K E
LUB
2. Install the cylinder head on the pressure plate.

Tightening torque 60 Nm

COOLING
3. Immerse the cylinder head with the pressure plate
into warm water (approx. 60°C) and pressurize with
compressed air to 2 bar.

FUEL
NOTICE

CONTROL
• Examine the cylinder head for air bubbling. If the air
bubbles are seen, replace the cylinder head.

SENSOR
Cylinder Head Mating Surface Check
Specifications
Height “A” (cylinder head parting surface - cylinder head cover parting surface) 140.9 ~ 141.1 mm
Minimum height after machining 140.9 mm
Flatness In longitudinal direction 0.075 mm
In transverse direction 0.075 mm
Permissible variation of parallelism of top parting surface to bottom in longitu-
within 0.1 mm
dinal direction
Peak-to-valley height 0.004 mm
Valve recess “a” Intake valve 0.74 ~ 0.86 mm
Exhaust valve -0.15 ~ 0.15 mm

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Measurement
1. Measure the cylinder head height “A”.
Limit Over 140.9 mm

NOTICE
• If the height is less than the limit, the cylinder head
must be replaced.

2. Insert the valves into the valve guides and measure

the recesses.

Valve recess “a” Intake Valve 0.74 ~ 0.86

Exhaust Valve -0.15 ~ 0.15

NOTICE
• If the measured value is out of the specified range,
machine the valve seat as much as necessary un-
til the specified value is achieved.

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GENERAL
Cylinder Head
Disassembly
Preceding Works:

ASSY
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks under
the tires. (transmission “N” position)

HOUSING
EXHAUST I N T A K E
1. Remove the EGR pipe.

LUB
COOLING
2. Disconnect the injector fuel lines, connector and

FUEL
preglow plug connector. Remove the cylinder head
cover.

CONTROL
CAUTION
• Cover the openings of fuel line with the protective
caps.

SENSOR
3. Rotate the crankshaft pulley to align the OT marks.
1) Align the mark (notch) on sprocket for cylinder
No.1 (exhaust) and for cylinder No.6 (intake).
(align the cylinder No.1 OT)

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6 02

4. Mark on the timing chain, intake camshaft sprocket

and exhaust camshaft sprocket for timing setting
during installation.

5. Remove the chain tensioner after removing the EGR

pipe and oil dipstick.

6. Remove the high pressure pump and mark on the

high pressure pump sprocket.

7. Remove the camshaft position sensor.

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8. Hold the camshafts and remove the intake camshaft

GENERAL
sprocket and exhaust camshaft sprocket.

ASSY
HOUSING
EXHAUST I N T A K E
9. Remove the upper guide rail with a sliding hammer.

LUB
COOLING
10. Remove the oil cooler and the intake manifold.

11. Remove the cylinder head bolts according to the FUEL

CONTROL
SENSOR
numerical sequence.
1) M8 x 25: 2EA
2) M8 x 50: 2EA
3) M12 x 177: 9EA
4) M12 x 158: 1EA (vacuum pump side)

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8 02

12. Remove the cylinder head.

CAUTION
• Inspect the cylinder head mating surface.
• Store the removed injectors and glow plugs so that
they will not be damaged.
• If there is a sign of oil leakage on the cylinder head
gasket, replace it with new one.

13. Measure the piston protrusion from the mating

surface.

Standard 0.765 ~ 1.055 mm

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 02 9

Reassembly

GENERAL
1. Measure the length of cylinder head bolts.
1) If the maximum length is exceeded by 2 mm,
replace the cylinder head bolt.

ASSY
HOUSING
EXHAUST I N T A K E
2. Install the cylinder head with the steel gasket.

NOTICE
• Make sure to place the “TOP” mark upward.

LUB
COOLING
3. Tighten the cylinder head bolts to specified torque

FUEL
and torque angle.

Step 1: 20 ± 2.0 Nm

CONTROL
Tightening torque Step 2: 85 ± 5.0 Nm
Step 3: 360° (120° x 3) + 10°

SENSOR
NOTICE
• Apply the oil on the bolt thread when installing.
• Always insert new washer first.
• The bolts at vacuum pump side are shorter than others.

4. Pull the timing chain over the cylinder head and install
the upper guide rail.

NOTICE
• Make sure that the convex surface of upper guide
rail faces to front side
• Be careful not to alter the timing point of high pres-
sure pump.

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10 02

5. Install the intake and exhaust camshaft sprockets

and the timing chain.

Tightening torque 25 Nm + 90°

NOTICE
• If the sprocket bolt is stretched over 0.9 mm, re-
place it with new one.
• Always install the intake camshaft sprocket first.

1) Make sure that the upper guide rail is installed

with proper direction.

2) Make sure that the timing chain is securely

seated on the guide rails.

NOTICE
• Make sure that the markings on camshaft sprocket
and timing chain are aligned.

6. Install the chain tensioner.

Tightening torque 65 ± 5.0 Nm

NOTICE
• Make sure that the EGR steel gasket is properly
installed.

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7. Rotate the crankshaft pulley two revolutions and

GENERAL
ensure that the OT mark on the crankshaft pulley
and the OT mark on the camshaft pulley are aligned.

ASSY
NOTICE
• If the markings are not aligned, reinstall the cylin-
der head.

HOUSING
EXHAUST I N T A K E
8. Install the cylinder head cover and the high pressure
pump housing.

NOTICE
• Apply the sealant on the bolt threads when install-
ing the high pressure pump.

LUB
COOLING
9. Remove the protective caps from the injector and

FUEL
install the new fuel supply pipes.

NOTICE

CONTROL
• The fuel pipes are not reusable to keep the clean-
ness and parts damage.

SENSOR

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12 02

Intake/Exhaust-Removal/Installation
1. Remove the cylinder head assembly.

2. Install the removed cylinder head on the assembly

board (special tool) and set the supporting bar and
lever (special tool) on the cylinder head.

3. Push the valve spring seat down with the lever and
remove the valve cotter, valve seat and valve spring.

4. Remove the valves from the cylinder head.

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Special Tools and Equipment

GENERAL
Name and Part Number Application

Y99220092B

ASSY
Compression pressure measuring
adapter and gauge

HOUSING
EXHAUST I N T A K E
Y99220082B
Supporting bar and lever

LUB
COOLING
Y99220162B

FUEL
Guide pin extractor

CONTROL
SENSOR
Y99220112B
Intake manifold guide pin

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14 02

CAMSHAFT ASSEMBLY
Preceding Work: Removal of cylinder head cover

Intake Camshaft and

Finger Follower and HLA Exhaust Camshaft Camshaft Sprockets

Cylinder Head

Camshaft Position Sensor Chain Tensioner

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Camshaft Position Sensor

GENERAL
Gap

ASSY
HOUSING
EXHAUST I N T A K E
Hall voltage

<Location of Camshaft Position Sensor> <Operation Principle of Hall Sensor>

The camshaft position sensor uses hall-effect to set the camshaft position and metallic-magnetic-material sensor
end is attached on the camshaft and then rotates with it. If sensor protrusion passes camshaft position sensor’s

LUB
semi-conductor wafer, magnetic field changes direction of electron on the semi-conductor wafer to the current flow
direction that passes through wafer from the right angle. When operation power is supplied from camshaft position
sensor, camshaft hall sensor generates signal voltage. The signal voltage will be 0V if protrusion and camshaft

COOLING
position sensor are near and 5 V if apart.
ECU can recognize that the No. 1 cylinder is under compression stroke by using this voltage signal (hall voltage).
The rotating speed of camshaft is half of the crankshaft and controls engine’s intake and exhaust valves. By install-
ing sensor on the camshaft, can recognize specific cylinder’s status, compression stroke or exhaust stroke, by

FUEL
using camshaft position when the piston is moving toward TDC (OT). Especially when started first, it is difficult to
calculate the stroke of a specific cylinder with only crankshaft position sensor.
Accordingly, camshaft position sensor is necessary to identify the cylinders correctly during initial starting. However,

CONTROL
when engine is started, ECU learns every cylinder of the engine with crankshaft position sensor signals so can run
the engine even though the camshaft position sensor is defective during engine running.

Pulse generation Cam angle ± 6°

SENSOR
Sensor air gap 0.45 ~ 1.80 mm
Tightening torque 10 ~ 14 Nm
Operating temperature - 40 ~ 130°C

Ground

Camshaft sensor

<Circuit Diagram of Camshaft Position Sensor>

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16 02

Disassembly
Preceding Works:
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks under
the tires. (transmission “N” position)

1. Remove the EGR pipe.

2. Disconnect the injector fuel lines, connector and

preglow plug connector. Remove the cylinder head
cover.

CAUTION
• Cover the openings of fuel line with the protective
caps.

3. Rotate the crankshaft pulley to align the OT marks.

1) Align the mark (notch) on sprocket for cylinder
No.1 (exhaust) and for cylinder No.6 (intake).
(align the cylinder No.1 OT)

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4. Mark on the timing chain, intake camshaft sprocket

GENERAL
and exhaust camshaft sprocket for timing setting
during installation.

ASSY
HOUSING
EXHAUST I N T A K E
5. Remove the chain tensioner after removing the EGR
pipe and oil dipstick.

LUB
COOLING
6. Remove the high pressure pump and mark on the

FUEL
high pressure pump sprocket.

7. Remove the camshaft position sensor. CONTROL

SENSOR

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18 02

8. Hold the camshafts and remove the intake camshaft

sprocket and exhaust camshaft sprocket.

9. Remove the camshaft bearing cap bolts so that

the tightening force can be relieved evenly.
1) Exhaust: #1, #3, #5
2) Intake: #6, #8, #10
However, there is no specific removal sequence.

3) Do not remove the bolts at a time completely.

Remove them step by step evenly or camshaft
can be seriously damaged.
4) Remove the exhaust camshafts and then
remove the intake camshaft.
• Exhaust: #2, #4
• Intake: #7, #9

10. Remove the finger follower and the HLA device.

Finger Follower

HLA

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 02 19

GENERAL
Reassembly Finger Follower

1. Install the HLA device and finger follower. Check

the HLA device with the diagnosis procedures before

ASSY
installation.

NOTICE

HOUSING
• Perform the air bleeding process if it has been
stored for a extended period of time.
HLA
• Make sure that it is properly installed on the locat-
ing pin.

EXHAUST I N T A K E
2. Place the bearing cap with the OT marks on both
camshafts facing upward.

NOTICE
• Apply the sealant on the cap (#12) for the vacuum
pump when installing.

LUB
Part number: 661 989 56 A0 (DB2210)
• Apply the oil on the bearing journals before
installation.

COOLING
3. Tighten the camshaft bearing cap bolts.

FUEL
1) Intake: #7, #9
2) Exhaust: #2, #4

3) Intake: #6, #8, #10 CONTROL

SENSOR

4) Exhaust: #1, #3, #5

Tightening torque 25 Nm

NOTICE
• Check the finger follower positions and align if
needed.

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20 02

4. Install the intake and exhaust camshaft sprockets

and the timing chain.

Tightening torque 25 Nm + 90°

NOTICE
• If the sprocket bolt is stretched over 0.9 mm, re-
place it with new one.
• Always install the intake camshaft sprocket first.

1) Make sure that the upper guide rail is installed

with proper direction.

2) Make sure that the timing chain is securely

seated on the guide rails.

NOTICE
• Make sure that the markings on camshaft sprocket
and timing chain are aligned.

5. Install the chain tensioner.

Tightening torque 65 ± 5.0 Nm

NOTICE
• Make sure that the EGR steel gasket is properly
installed.

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6. Rotate the crankshaft pulley two revolutions and

GENERAL
ensure that the OT mark on the crankshaft pulley
and the OT mark on the camshaft pulley are aligned.

ASSY
NOTICE
• If the markings are not aligned, reinstall the cylin-
der head.

HOUSING
EXHAUST I N T A K E
7. Install the cylinder head cover and the high pressure
pump housing.

NOTICE
• Apply the sealant on the bolt threads when install-
ing the high pressure pump.

LUB
COOLING
8. Remove the protective caps from the injector and

FUEL
install the new fuel supply pipes.

NOTICE

CONTROL
• The fuel pipes are not reusable to keep the clean-
ness and parts damage.

SENSOR

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22 02

Special Tools and Equipment

Name and Part Number Application

Y99220152B
HLA remover

Y99220142B
Stem seal installer

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 02 23

TIMING CHAIN ASSEMBLY

GENERAL
Chain Drive System

ASSY
System Layout

HOUSING
EXHAUST I N T A K E
Oil injecting direction

LUB
COOLING
FUEL
CONTROL
1. Exhaust camshaft sprocket 7. Oil pump tensioner

SENSOR
2. Upper guide rail 8. Oil pump sprocket
3. Intake camshaft sprocket 9. Crankshaft sprocket
4. Clamping guide rail 10. Oil nozzle
5. HP pump sprocket 11. Tensioner guide rail
6. Lower guide rail 12. Chain tensioner

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Chain
1. Chain type: Double Bush
2. Pitch: 9.525 mm
3. Load limits: 19,000 N
4. No. of links: 148 EA
5. Overall length: 1409.7 mm
6. Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 7.0485 mm)

Chain Tensioner

Check valve

* Check valve opening pressure: 0.2 ~ 0.5 bar

The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By
doing so, can reduce wears of each guide rail and sprocket.

65 ± 5.0 Nm
Tightening torque
(Installed on the cylinder head)

Guide Rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.

1. Location of guide rail

1) Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
2) Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
3) Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
4) Lower guide rail: Between HP pump sprocket and crankshaft sprocket

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Timing Setting

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
Sprocket
marking:
4 points

COOLING
(Gold marking)

FUEL
CONTROL
1. Check marking links on the chain (Gold marking)
2. Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( )

SENSOR
3. Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( )
4. Align another marking link to HP pump sprocket marking ( )

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Removal and Installation

1. Remove the cylinder head assembly.

2. Remove the oil pan.
3. Remove the chain guide rail with a sliding hammer.
4. Remove the chain cover.

5. Remove the oil pump drive chain.

6. Remove the upper guide rail while pushing the
retaining spring with a screwdriver.
7. Remove the lower guide rail.
8. Remove the oil pump drive chain.

9. Remove the tensioner guide rail.

10. Remove the timing chain.
11. Install in the reverse order of removal.

NOTICE
• Thoroughly clean the removed components before
installing.

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CYLINDER BLOCK

GENERAL
ASSY
Deep head bolt thread to prevent the
deformation at cylinder bore surfaces

HOUSING
EXHAUST I N T A K E
LUB
Water jacket design to in-
crease the cooling efficiency

COOLING
FUEL
CONTROL
Cambering type skirt to reduce the noise

SENSOR

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System Characteristics
1. Rib design by considering strength against engine vibrations and weight
2. Cambering type skirt design on case housing wall to reduce the engine noise
3. Water jacket design to increase the cooling efficiency of cylinder bore bridge
4. Deep head bolt thread to prevent the deformation at cylinder bore surfaces
5. Reinforcement of strength
1) Main bearing housing / Main bearing cap
2) Extended main bearing cap bolt
6. Reducing the noise, vibration and harshness (NVH)
1) Minimize the vibration by adding external ribs
2) Adding the ribs around oil pan mating surface

Knock Sensor
Two knock sensors are located on the cylinder block (intake manifold side).
To detect engine vibration under abnormal combustion, knock sensor has piezoelectric element fixed on the
vibration plate and this vibration plate is fixed on the base. If happens knocking, pistons or connecting rods
vibrate and occurs heavy sounds that hit metal. Knock sensor is used to detect those knockings caused by
abnormal combustions. It controls idling stabilities and turns on the engine warning light when detects injector
damages. And also controls pilot injection very precisely during MAP learning.
When knock sensor is defective, engine ECU corrects injection timing based on MAP values like engine speed,
intake air volume and coolant temperature.

Before checking the knock sensor unit, be sure to check the tightening torque of the sensor and connector
connecting conditions.
Insulating resistance Min. 1 MΩ
Resonance frequency 25 kHz
Operating temperature - 40 ~ 150°C
26 ± 8 mV/g (at 5 kHz)
Output voltage 22 ~ 37 mV/g (3 ~ 10 kHz)
22 ~ 57 mV/g (10 ~ 20 kHz)
Tightening torque 20 ± 5 Nm

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GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
<Location of Knock Sensor>

1. Sensor housing 6. Upper contact plate

2. Nut 7. Piezo element
3. Disc spring 8. Lower contact plate

LUB
4. Weight 9. Body
5. Insulation disc 10. Terminal

COOLING
FUEL
NOTICE

CONTROL
• The knock sensor should be tightened with the specified tightening torque. Otherwise, the engine output may
be decreased and the “ENGINE CHECK” warning lamp may come on. The internal resistance of the sensor is
approx. 4.7 kW.

SENSOR
Ground
Knock
sensor
Signal

Signal

Knock
sensor
Ground
(Except D20DT)

<Circuit Diagram of Knock Sensor>

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CRANKSHAFT
Preceding Works: Removal of end cover
Removal of pistons
Removal of crankshaft sprocket

1. Crankshaft main bearing shells, upper 5. Lower thrust bearing

2. Upper thrust bearing 6. Crankshaft main bearing cap
3. Crankshaft 7. Crankshaft thrust bearing cap
4. Crankshaft main bearing shells, lower 8. 12-sided stretch bolt ....... 55 ± 5.0 Nm, 90° + 10°

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ARRANGEMENT OF THRUST WASHERS AND BEARINGS

GENERAL
2 3

ASSY
HOUSING
EXHAUST I N T A K E
1

LUB
4 5

COOLING
1. Crankshaft 4. Crankshaft main bearing shells, lower
2. Crankshaft main bearing shells, upper 5. Lower thrust bearing
3. Upper thrust bearing

FUEL
NOTICE

CONTROL
• The clearance between bearing shell and bore and between bearing shell and journal are various. Refer to
the table on next page to select bearings when installing.

SENSOR

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32 02

Dimensions of Crankshaft Main Bearing

Color Crankshaft Journal Upper Main Bearing Lower Main Bearing
Blue 61.965 ~ 61.960 2.260 ~ 2.255 2.260 ~ 2.255
Yellow 61.960 ~ 61.955 2.265 ~ 2.260 2.265 ~ 2.260
Red 61.955 ~ 61.950 2.270 ~ 2.265 2.270 ~ 2.265
White 61.950 ~ 61.945 - 2.275 ~ 2.270
Violet 61.945 ~ 61.940 - 2.280 ~ 2.275

Bearing Clearance (mm)

Description Crankshaft Bearing Thrust Bearing

When new 0.027 ~ 0.051 0.026 ~ 0.068
Radial clearance
Wear limit Max. 0.070 Max. 0.080
When new 0.100 ~ 0.254 -
Axial clearance
Wear limit Max. 0.300 -

Matching the Fit Bearing Journal Width to Thrust Washers (mm)

Fit bearing Journal Width Thrust Washer Thickness

26.300 ~ 26.333 2.15
26.400 ~ 26.433 2.20
26.500 ~ 26.533 2.25
26.700 ~ 26.733 2.35
26.800 ~ 26.833 2.40

NOTICE
• Measure the crankshaft axial clearance and correct if necessary with appropriate thrust washers.
• Thrust washers of the same thickness must be installed on both sides of the fit bearing.

Matching the Crankshaft Bearing Shells to Basic Bearing Bore in

Crankcase
Marking of Basic Bearing Bore in Lower Mating Surface Relevant Crankshaft Bearing Shell With Color Coding
1 punch mark or blue blue or white - blue
2 punch marks or yellow yellow or white - yellow
3 punch marks or red red or white - red

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Matching Crankshaft Bearing Shells to Basic Bearing Journal of

GENERAL
Crankshaft
Marking of Bearing Journals on Crank Webs Relevant Crankshaft Bearing Shell With Color Coding

ASSY
blue or white - blue blue or white - blue
yellow or white - blue yellow or white - yellow
red or white - blue red or white - red

HOUSING
EXHAUST I N T A K E
Selection of Upper Main Bearing
Shell
Punch Mark Color
• Blue
• • Yellow

LUB
• • • Red

COOLING
Selection of Lower Main Bearing

FUEL
Shell
Mark Color

CONTROL
B Blue
Y Yellow
R Red

SENSOR
W White
V Violet

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Crankshaft Position Sensor

Permanent
magnet
Iron
coil
Standard
position

Ring gear

<Location of Crankshaft Position Sensor> <Structure of Crankshaft Position Sensor>

The crankshaft position sensor is located near to flywheel on the rear of cylinder block. It generates AC voltage
between increment type driven plate that fixed on flywheel inside. The sensor consists of soft iron core that winded
copper wire on permanent magnet and generates sign wave AC voltage when magnetism on the sensor wheel
passes the sensor.
When the crankshaft rotates, ‘+’ signal will be generated from near the front edge and ‘-’ signal will be generated from
near the rear edge among teeth on the driven plate near to crankshaft position. The AC voltage increases as the
engine speed increases, however, no signal occurs from the 2-missing-tooth on the increment type driven plate. By
using these teeth, ECU recognizes TDC of No. 1 and 5 cylinders.
ECU converts the alternative signals into digital signals to recognize crankshaft position, piston position and engine
speed. The piston position that coupled with crankshaft is main factor in calculating injection timing. By analyzing the
reference position and camshaft position sensor, can recognize No. 1 cylinder and calculate the crankshaft speed.

<Drive Plate>

A. Distance between ‘+’ max. voltage and ‘-’ max. voltage a. Front edge
b. Rear edge
c. 2-missing-tooth

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GENERAL
ASSY
Ground

HOUSING
EXHAUST I N T A K E
Signal
Crankshaft
Drive plate position sensor

<Circuit Diagram of Crankshaft Position Sensor>

LUB
Output voltage Min. voltage: 1.0 V (40 rpm, air gap: 1.3 mm)
( 1 ~ 150 V) Max voltage: 150 V (7000 rpm, air gap: 0.3 mm)
Sensor unit coil resistance (Ω)

COOLING
1,090 ± 15 %
Sensor air gap 0.7 ~ 1.5 mm
Operating temperature - 40 ~ 150°C
Tightening torque 6 ~ 8 Nm

FUEL
CONTROL
SENSOR

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36 02

TORSIONAL VIBRATION DAMPER

Laser welding

Pin

Cover

Hub
Bearing

Bushing

Inertia ring
Pin
Silicone oil

System Description
1. Components: Hub, inertia ring, cover, bearing, bushing, silicone oil
2. Functions: The crankshaft pulley optimizes the drive system by reducing the amount of torsional vibration in
crankshaft. Conventional rubber damper is limited in changing materials (rubbers) to absorb vibration,
but this crankshaft pulley (viscous damper), using silicone oil, takes advantage of less changing
viscosity according to the temperature.

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DISASSEMBLY AND REASSEMBLY

GENERAL
1. Unscrew the bolts and remove the connecting rod
journal bearing and bearing caps.

ASSY
NOTICE
• Position the #1 piston at TDC and remove the pis-
ton connecting rod journal bearing caps.

HOUSING
2. Remove the bearing cap bolts.
3. Remove the bearing caps.

EXHAUST I N T A K E
NOTICE
• The crankshaft bearing caps are marked with
stamped numbers. Start to remove from the crank-
shaft pulley side.

LUB
• Do not mix up the bearing shells.

COOLING
4. Remove the bearing caps and lower thrust bearing.
5. Separate the lower bearing shells from the bearing
caps.

FUEL
6. Remove the crankshaft.
7. Remove the upper thrust washers.

CONTROL
8. Remove the upper bearing shells from the crankcase.

NOTICE

SENSOR
• Do not mix up the bearing shells.

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38 02

Crankshaft - Reassembly
1. Thoroughly clean the oil galleries and check the
journal section and bearings. Replace if necessary.

2. Coat the upper thrust washers with oil and insert

into the crankcase so that the oil grooves are facing
the crank webs (arrow).
3. Coat the lower thrust washers with oil and insert
into the crankcase so that the oil grooves are facing
the crank webs (arrow).

NOTICE
• The retaining lugs should be positioned in the
grooves (arrow).

NOTICE
• If the maximum permissible length of L= 63.8 mm
is exceeded, the 12-sided stretch bolts should be
replaced.

4. Coat the new crankshaft with engine oil and place it

on the crankcase.
5. Install the crankshaft bearing caps according to the
markings and tighten the bolts.

Installation Notice
Tightening torque 55 ± 5 Nm + 90° + 10°

• Install from #1 cap.

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6. Position the #1 piston at TDC and install the

GENERAL
crankshaft.
7. Install the piston connecting rod journal to the
crankshaft journal and tighten the bolts.

ASSY
8. Measure the crankshaft bearing axial clearance.
1) When new: 0.100 ~ 0.266 mm
2) When used: 0.300 mm

HOUSING
9. Rotate the crankshaft by hand and check whether
it rotates smoothly.

EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

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40 02

FLYWHEEL

DUAL MASS FLYWHEEL (DMF, MANUAL TRANSMISSION EQUIPPED VEHICLE)

Primary wheel
Ring gear
Trigger ring

Primary wheel
Secondary
wheel

Plastic bushing

System Description
This flywheel is installed to the rear end of crankshaft and transfers the output from the engine to the power train
mechanism. When starting the engine, this drive the crank train mechanism initially by using the power from the
start motor. Also, DMF measure the crankshaft speed, sends the signals to ECU, and controls the ignition timing.

Conventional flywheel DMF

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Structure

GENERAL
Function and characteristics
1. When the output changes from the engine is high during

ASSY
power stroke ( ): The damper absorbs the shocks to
reduce the changes to transmission.
2. When the output changes from the engine is low during

HOUSING
compression stroke ( ): The damper increases the
torque changes to clutch.

<Example of DMF operation>

EXHAUST I N T A K E
<Torque change curve of engine and drive shaft>

Conventional system DMF

Angular acceleration amplitude

Engine

LUB
Engine
[1/s2]

COOLING
Transmission
Transmission

FUEL
Speed [rpm] Speed [rpm]

CONTROL
System Characteristics
Function Advantages of DMF

SENSOR
1. Filters irregularities of engine: The secondary 1. Improved torque response by using 3-stage type
flywheel operates almost evenly so does not cause spring: Strengthens the torque response in all
gear noises ranges (low, medium, and high speed) by applying
2. The mass of the primary flywheel is less than respective spring constant at each range.
conventional flywheel so the engine irregularity 2. Stable revolution of the primary and secondary
increases more (less pulsation absorbing effect) wheel by using planetary gear: Works as auxiliary
3. Transmission protection function: Reduces the damper against spring changes
torsional vibration to powertrain (transmission) by 3. Less heat generation due to no direct friction against
reducing the irregularity of engine spring surface: Plastic material is covered on the
spring outer surface
Characteristics of DMF
4. Increased durability by using plastic bushing
1. Reduced vibration noise from the powertrain by (extends the lifetime of grease)
blocking the torsional vibrations
2. Enhanced vehicle silence and riding comforts: reduced
engine torque fluctuation
3. Reduced shifting shocks
4. Smooth acceleration and deceleration

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42 02

PISTON AND CONNECTING ROD

1. No.1 compression ring 3. Oil ring

2. No.2 compression ring

Description ENG
Cylinder bore diameter φ 86.2 (0~0.018) mm
Piston outer diameter (D1) φ 86.133 (±0.009) mm
Clearance between bore and piston 74
Piston cooling gallery Applied
Pin offset 0.15 mm (Thrust)
Compression ratio 17.5 : 1
Length of piston pin 71.2 mm
Material of top ring / coating Steel / Gas nitride
Tightening torque of connecting rod bolt 40 ± 5.0 Nm, 90° + 10°
Permissible weight difference of connecting rod 4g
Thickness of connecting rod bearing (Red) 1.806 ~ 1.809 mm
Thickness of connecting rod bearing (Yellow) 1.809 ~ 1.812 mm
Thickness of connecting rod bearing (Blue) 1.812 ~ 1.815 mm

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PISTON RING

GENERAL
1. No.1 compression ring
2. No.2 compression ring
3. Oil ring

ASSY
5. Coil spring and oil control ring
6. Hook spring

HOUSING
EXHAUST I N T A K E
LUB
COOLING
Replacement of Piston Ring

FUEL
1. Measure piston ring end gap.
1) Piston ring end gap (mm)

CONTROL
1st groove: 0.20 ~ 0.35
2nd groove: 0.20 ~ 0.35
3rd groove: 0.20 ~ 0.40

SENSOR
2) Clearance between piston ring and piston (mm)
1st compression ring: 0.075 ~ 0.119
2nd compression ring: 0.050 ~ 0.090
3rd oil ring: 0.030 ~ 0.070

3. Install the piston so that “Y” marking on piston head

is facing in the direction of travel. Arrange the piston
ring ends to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away
from the ring end.

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CYLINDER INNER DIAMETER AND PISTON SIZE

(Unit : mm)
Code Used piston Cylinder Diameter Piston Diameter
A A or X 86.200 ~ 86.206 86.124 ~ 86.130
X A, B or X 86.206 ~ 86.212 86.129 ~ 86.137
B B or X 86.212 ~ 86.218 86.136 ~ 86.142
+5 +5 86.250 ~ 86.260 86.167 ~ 86.181
+ 10 + 10 86.300 ~ 86.310 86.217 ~ 86.231

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DISASSEMBLY AND REASSEMBLY

GENERAL
1. Install the compression ring and oil ring on the piston
with a special tool.

ASSY
HOUSING
EXHAUST I N T A K E
Arrange the piston ring ends to be 120° apart.

NOTICE
• Install the No.1 and No.2 pistons so that “Y” mark-
ing on piston head is facing upward.
• No.1 piston ring is thicker than No.2 piston ring.

LUB
• Arrange the oil ring end to opposite position of cur-
rent ring end.
• Oil ring is not directional.

COOLING
• Make sure that the piston ring end is not aligned to
axial direction and lateral direction.

2. Check the clearance of piston oil ring and compression

FUEL
ring with a thickness gauge and adjust if necessary.

1st groove 0.20 ~ 0.35 mm

CONTROL
2nd groove 0.20 ~ 0.35 mm
3rd groove 0.20 ~ 0.40 mm

Piston ring end play (mm)

SENSOR
1st groove: 11.0 mm
2nd groove: 10.5 mm
3rd groove: 7.0 mm

3. Check the clearance of piston rings with a thickness

gauge and adjust if necessary.

No.1 compression ring 0.075 ~ 0.119 mm

2nd compression ring 0.050 ~ 0.090 mm
3rd oil ring 0.040 ~ 0.080 mm

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4. Fit the piston onto connecting rod so that the

marking on piston crown and locking slot are facing
to straight ahead direction.

NOTICE
• Install the piston so that the piston recess (marking)
or the stamped surface of connecting rod is facing
to straight ahead direction.

5. Lubricate piston pin and push in by hand.

NOTICE
• Do not heat up the piston.

6. Place new snap rings into the grooves.

NOTICE
• The snap rings should be replaced with new one.

7. Lubricate the cylinder bore, connecting rod bearing

journals, connecting rod bearing shells and pistons.

8. Push piston into the cylinder with a wooden stick.

9. Insert connecting rod bearing shells.

NOTICE
• The upper and lower connecting rod bearings have
same appearance. Therefore, make sure to check
the part number before replacing them.
• Install bearing rod bearing cap so that the retain-
ing lugs are on the same side of the connecting rod
bearing.

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10. Measure stretch shaft diameter of the connecting

GENERAL
rod bolts.

Limit “C” 7.1 mm

ASSY
HOUSING
EXHAUST I N T A K E
11. Lubricate the new connecting rod bolts and tighten.

Installation Notice
40 ± 5.0 Nm,
Tightening torque
90° + 10°

LUB
• End play of connecting rod cap

Specified value 0.5 ~ 1.5 mm

COOLING
12. Position piston to TDC and measure the distance

FUEL
between piston and mating surface of crankcase.

Permissible piston
0.765 ~ 1.055 mm

CONTROL
protrusion

• Measure at both ends of axial direction.

SENSOR

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Special Tools and Equipment

Name and Part Number Application

Y99220122B
Piston protrusion measuring jig

Y99220172B
Piston insertion jig

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 02 49

HIGH PRESSURE PUMP (HPP)

GENERAL
COMPONENTS LOCATOR

ASSY
HOUSING
EXHAUST I N T A K E
High pressure
line
Low pressure Venturi return line
line

LUB
Fuel temperature sensor

COOLING
IMV connector

FUEL
Inlet Metering
Valve (IMV)

CONTROL
SENSOR
High pressure
supply line

1. Inlet Metering Valve (IMV) 7. Low pressure pump

2. Hydraulic pressure head 8. Fuel temperature sensor
3. Plunger 9. Venting
4. Drive shaft and cam ring 10. High fuel pressure supply line
5. Housing 11. Pressure regulator
6. Roller and shoe

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High Pressure Pump and Fuel System

Injector pipe

Injector pipe
Protective cap

Return
tube
Fuel rail
(common rail)

Injector Upper bracket for

high pressure pipe
High
pressure
Injector pipe
Injector clamp washer

HP pump

Bearing housing

Sprocket

HP pump
bracket

Gasket

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Installation of High Pressure Pump

GENERAL
Vehicle with Engine
HP pump

ASSY
Gasket

HOUSING
Sprocket

EXHAUST I N T A K E
Nut Bracket

Bearing
housing

Bolt

LUB
COOLING
FUEL
CONTROL
SENSOR

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52 02

DISASSEMBLY AND REASSEMBLY

Preceding Works:
1. Removal of fan belt (including cooling fan and fan
clutch) and fan shroud
2. Removal of intake manifold assembly
3. Removal of water pump pulley
4. Removal of auto tensioner
5. Removal of EGR pipe
6. Removal of oil dipstic gauge

NOTICE
• To prevent oil leaks, store the removed auto
tensioner it upright position.
• Be careful not to damage the rubber bellows.
• Plug the oil ports for HP pump with sealing caps.

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HP Pump - without SST

GENERAL
Disassembly

Preceding Works:

ASSY
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks
under the tires. (transmission “N” position)

HOUSING
1. Turn the auto tensioner counterclockwise and remove

EXHAUST I N T A K E
the fan belt.

NOTICE
• Slacken the pulley bolt.

LUB
COOLING
2. Remove the engine belt pulleys.
1) Cooling fan pulley
2) Coolant pump pulley

FUEL
CONTROL
SENSOR
3. Unscrew lower bolt (13 mm) and upper bolt (24 mm)
and remove the auto tensioner.

NOTICE
• To prevent oil leaks, store the removed auto
tensioner in upright position.
• Pump the auto tensioner several times before in-
stalling it.

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4. Remove the high pressure pump housing.

Preceding Work: Remove the No.2 EGR pipe.

5. Align the OT mark by rotating the crankshaft.

1) Open the oil filler cap and check if the OT mark
on crankshaft is aligned to the notch on the
camshaft.

6. Unscrew the bolts and remove the vacuum

modulator bracket.
1) Disconnect the high pressure pump and vacuum
modulator connector.
2) Disconnect the fuel lines to high pressure pump.
3) Plug the openings of pipes and ports with
protective caps to keep the cleanness of the
fuel system.
4) Remove the high pressure fuel pipe between
HP pump and common rail.

7. Rotate the crankshaft clockwise so that the HP

pump sprocket holes are aligned to the bolt holes.

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8. Hold the HP pump sprocket and slacken the center

GENERAL
bolt.

ASSY
HOUSING
EXHAUST I N T A K E
9. Slacken three HP pump mounting bolts until they
rest on the sprocket.

LUB
COOLING
FUEL
10. Loosen the HP pump center nut by tapping it with
a hammer.

CONTROL
NOTICE
• Tap the center bolt with a hammer after tightening.
• Make sure that the center bolt is securely tightened.

11. Remove the remaining bolts with the same manner SENSOR
and remove the high pressure pump.

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56 02

Reassembly

1. Replace the HP pump gasket with new one (cannot

be reused).

2. Tighten the HP pump bolts.

Tightening torque 25 Nm

3. Hold the HP pump sprocket and tighten the center

nut.

Tightening torque 65 Nm

NOTICE
• The center nut should be replaced once removed
(cannot be reused).
• Tighten the center nut with the specified tightening
torque.

4. Install the vacuum modulator bracket.

NOTICE
• Replace the fuel lines to HP pump with new ones
(cannot be reused).
• Make sure that the connectors are installed to
the correct locations. (RR: white tape)

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5. Apply the sealant to the HP pump housing and

GENERAL
tighten the bolts.

NOTICE

ASSY
• Sealant (DB2210): 661 989 56 A0

HOUSING
EXHAUST I N T A K E
6. Install the auto tensioner and belt pulleys.

82 ± 6.0 Nm
Tightening torque
32 Nm

LUB
COOLING
7. Rotate the crankshaft pulley two revolutions and

FUEL
ensure that the OT mark on the crankshaft pulley
and the OT mark on the camshaft pulley are aligned.

CONTROL
NOTICE
• Open the oil filler cap and check if the OT mark on
crankshaft is aligned to the notch on the camshaft.

SENSOR

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58 02

HP Pump - with SST

Special Service Tool

SST Installation HP Pump Installation

HP pump mounting
hole on engine

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GENERAL
Preceding Works:
1. Disconnect the negative battery cable.
(If necessary, remove the battery.)

ASSY
¼±Çà ÀÛ¾÷
2. Remove the front air duct assembly.
3. Remove the PWM electric fan.

HOUSING
EXHAUST I N T A K E
NOTICE
• To prevent from the oil leaking, put the removed auto tensioner in up-light position.
• Be careful not to damage the rubber bellows when removing the auto tensioner.
• Plug all fuel supply ports with seal caps (including removed ones).

LUB
Removal

1. Take off the fan belt while turning the auto tensioner

COOLING
counterclockwise.

FUEL
CONTROL
SENSOR
2. Remove the auto tensioner from the engine.

* To prevent from the oil leaking, put the removed auto tensioner in up-light position.

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60 02

3. Unscrew four bolts and remove the water pump

pulley.

4. Open the caps (A, B) and unscrew the mounting bolts to remove the idle pulleys (A, B).

Open Caps Unscrew Mounting Bolts

Idle pulleys caps

5. Remove the idle bracket.

Unscrew Mounting Bolt Remove Idle Bracket

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6. Remove the oil separator and EGR cooler pipe. Remove the chain tensioner and rotate the crankshaft so that

GENERAL
the upper holes on HP pump sprocket are horizontally aligned. (At this moment, the holes on sprocket are
aligned to mounting bolts for HP pump.)

Remove Chain Tensioner HP Pump Sprocket

ASSY
Rotate the sprocket so that the upper holes on
HP pump sprocket are horizontally aligned.

HOUSING
Chain tensioner

EXHAUST I N T A K E
* Three HP pump mounting bolts are visible.

LUB
7. Remove the vacuum modulator bracket.
A. Disconnect the vacuum modulator connector and
fuel line.

COOLING
B. Disconnect the fuel line to high pressure pump.
(To keep cleanness, plug the opening with a A. Connector
sealing cap.)

FUEL
B. Fuel line

A. Connector

CONTROL
SENSOR
8. Remove the center nut on high pressure pump and loosen three hexagon bolts.

Center Nut Mounting Bolts

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9. Install the special service tool on the high pressure pump sprocket.

10. Separate the sprocket from the high pressure pump by turning the center bolt on special service tool.

11. Remove the special service tool and unscrew three mounting bolts to remove the high pressure pump.

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 02 63

GENERAL
NOTE

1. The gasket for high pressure pump cannot be reused. It should be replaced with new one if removed.
2. Place an alignment mark on the high pressure pump shaft and key.

ASSY
HOUSING
EXHAUST I N T A K E
Key
groove

Alignment
mark

LUB
COOLING
FUEL
CONTROL
SENSOR

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64 02

Installation

1. Install in the reverse order of removal. (However,

temporarily tighten three mounting bolts first, then
fully tighten the center bolt, mounting bolts and
center nut in order.

Tightening torque

Hexagon mounting bolt 25 ± 2.5 Nm

Center nut 65 ± 5 Nm

2. Install the vacuum modulator bracket.

NOTICE
• The vacuum modulator connector and vacuum hose
should be connected to correct positions. The wir-
ing with white tape should face to the rear-end of
engine.

3. Apply the specified sealant (DB2210: 661 989

56 A0) and tighten the bolts to the specified
tightening torque.
4. Install the accessories.

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 INTAKE SYSTEM
03

TABLE OF CONTENTS
AIR FLOWS ............................................................. 3

INTAKE SYSTEM LAYOUT ..................................... 4

Work flow of intake system ........................................................ 4
Components ..............................................................................7
Precautions when installing intake system ................................ 9
Air flow sensor (hot film air mass sensor) ................................ 13
Intercooler ................................................................................ 17
Intake manifold assembly ........................................................ 20
 03 3

AIR FLOWS

GENERAL
ASSY
Intake valve
(in combustion chamber)

HOUSING
EXHAUST I N T A K E
Intake manifold

Air cleaner

LUB
COOLING
Turbo
charger Engine

FUEL
CONTROL
SENSOR
HFM sensor

Intake air outlet hose Intercooler Intake air inlet hose

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4 03

INTAKE SYSTEM LAYOUT

WORK FLOW OF INTAKE SYSTEM

Combus-
VGT
Air HFM Inter- Intake tion
Turbo-
Cleaner Sensor cooler Manifold Chamber
charger
in Engine

VGT Turbocharger

Turbocharger
actuator

Exhaust Intake
pipe (diesel (air cleaner)
catalytic
converter)
Com-
pressed air
Exhaust gas (intercooler)
Air Cleaner

HFM Sensor
The HFM sensor is installed in the air intake passage between the
air cleaner and the intake manifold. It measures the air volume
supplied to the combustion chamber and the air temperature.

Major Functions
Front Air Duct
• It controls the EGR feedback.
• It controls the pressure control valve for the
turbocharger booster.

1. Plug-in sensor
2. Cylinder housing
3. Protection grid
4. Hybrid cover
Plug-in 5. Measuring duct cover
sensor
6. Housing
7. Hybrid
Tem- 8. Sensor
perature
sensor Protection 9. Mounting plate
grid 10. O-ring
11. Temperature sensor
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 03 5

GENERAL
EGR Valve and Its Location (* For details, refer to “EGR” section.)

ASSY
Intake
air
Intake Intake
air Intake manifold
manifold

HOUSING
Exhaust
gas

EXHAUST I N T A K E
Exhaust gas

Intake Manifold

Vacuum modulator
for turbocharger
actuator

LUB
EGR vacuum

COOLING
modulator

Vacuum Modulator

EGR Vacuum

FUEL
valve pump

CONTROL
SENSOR
IP interior fuse Engine ECU
(RH) No. 96
No.63-7.5A

Turbocharger Intercooler
The charging efficiency may be lowered or the knock-
ing may happen as the intake air is heated and the
density of air is lowered. The intercooler is the de-
vice which cools the supercharged air.

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6 03

Layout

Intake
manifold
Tightening torque
(M8-nut)
: 35 ± 3.5 Nm
Tightening torque
(M8X50/133-10 EA)
: 25 ± 2.5 Nm

EGR-RH pipe
assembly
EGR valve assembly EGR valve
Tightening torque gasket
(M6X25-4 EA)
: 10 ± 1.0 Nm

EGR pipe
gasket EGR pipe
assembly
Tightening torque
Tightening torque EGR pipe (M6X16-2 EA)
(M6X16-2 EA) EGR-LH pipe : 10 ± 1.0 Nm
gasket
: 10 ± 1.0 Nm assembly

Tightening torque
(M8X25/30-4 EA)
: 25 ± 2.5 Nm Tightening torque
(M6X16-2 EA)
: 10 ± 1.0 Nm

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 03 7

COMPONENTS

GENERAL
Intake Manifold Assembly
The intake manifold assembly is built for the optimized mixture of the EGR gas in the intake chamber when the

ASSY
compressed air in the turbocharger is sent to the intake port. The intake port is composed of the dual port (tangential
and helical port) which increases the swirl ratio in mid/low operating range, improves acceleration/fuel consumption
and decreases particle materials. However, there are some differences in the form of the EGR valve and 4-cylinder

HOUSING
engine.

NOTICE

EXHAUST I N T A K E
• The inlet port and coolant outlet port is integrated together. Therefore, be careful not to let the residual cool-
ant in the manifold enter the inlet port when removing the intake manifold. Also, replace the gasket with a
new one and tighten it to the specified torque (25 ± 2.5 Nm).

The SUS + Rubber coating is applied to the intake manifold gasket to prevent the air leakage and optimize the
sealing effect.

Intake Manifold

LUB
COOLING
Coolant
emission port

FUEL
Coolant
EGR pipe emission port
(RH)

CONTROL
Intake air

SENSOR
(intercooler)

Vacuum modulator to the EGR valve

Exhaust
gas EGR pipe (LH)

Incoming of intake air

Incoming of intake air
and exhaust gas
(No operation of EGR valve)
(Operation of EGR valve)
EGR pipe
(center)

Intake Intake
air air
Coolant
emission port

Exhaust gas

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8 03

Turbocharger Intercooler Assembly

The turbocharger is designed to improve the engine power by introducing more air (oxygen) into the engine.
However, the intake air is heated during the compression process in the turbocharger compressor and the density is
lowered.
The intercooler is the device which cools (50 ~ 60°C) the air entering the engine from high temperature (100 ~ 110°C)
to maintain the turbocharging efficiency.
Thus, more air is entered the cylinder than the engine only with the turbocharger to give more power.

Intercooler

Removal and Installation

For removal and installation procedures, refer to the “Cooling system”
section in DI engine service manual.

INTAKE SYSTEM CHANGED BY

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 03 9

PRECAUTIONS WHEN INSTALLING INTAKE SYSTEM

GENERAL
Intake (Inlet/Outlet) Hose and EGR Pipe
The clamps of hoses and EGR pipe should be tightened to the specified tightening torque when installing the engine

ASSY
assembly or servicing on the air cleaner duct, the turbocharger and the intercooler.

HOUSING
1. Hose between air cleaner and turbocharger 2. Hose between turbocharger and intercooler

Tightening torque Tightening torque

6 ~ 7 Nm 6 ~ 7 Nm

EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR
4. Fixing clamps on inlet hose (intake
3. Connections of EGR pipe manifold and intercooler)

Tightening torque Tightening torque

10 ± 1.0 Nm 6 ~ 7 Nm

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10 03

Precautions When Installing

: The clamps on the hoses should be tightened to the specified tightening torque when installing the engine
assembly or servicing on the air cleaner duct, the turbocharger and the intercooler.

1. Symptoms
: Insufficient engine power, smoke or noise when accelerating (whistle noise).

2. Cause
: Clamp is out of place due to the turbocharging pressure or inproper tightening torque.

3. Correction
- Check if the clamp is out of place or the intercooler is leaking.
- Always observe the tightening torque when installing the related parts.
- Do not use a screwdriver. Always use a torque wrench when tightening the clamps.
Tightening torque of
6 ~ 7 Nm
intake hose clamp

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 03 11

GENERAL
Air Cleaner Element - Replacement
Preceding Work: Disconnection of negative battery
cable

ASSY
1. Disconnect the HFM sensor connector.
2. Loosen the locking clamp and remove the intake duct.

HOUSING
EXHAUST I N T A K E
3. Unscrew the screws and remove the air cleaner cover.

LUB
COOLING
4. Remove the air cleaner element. Clean or replace the

FUEL
element as required.

CONTROL
SENSOR

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12 03

Air Cleaner Housing

- Removal and Installation
Preceding Work: Removal of air cleaner cover

1. Set aside the return hose and remove the coolant

reservoir bolts.

2. Remove the air cleaner housing bolts.

3. Install in the reverse order of removal.

Air Cleaner Housing/Element - Check

1. Check the air cleaner body, cover and packing for
deformation, corrosion and damage.
2. Check the air duct for damage.
3. Check the air cleaner element for clogging,
contamination and damage. If the element is partially
clogged, remove the dust or foreign materials with the
compressed air. If the contamination is severe, replace
it with new one. Also, be careful not to contaminate
during the replacement.

4. Check the air cleaner housing for clogging, contamination

and damage.
5. If the inside of housing is contaminated, remove the
contaminants.

NOTICE
• When cleaning the air cleaner with compressed air,
direct the air from inside (engine) to outside
(ambient air). Otherwise, contaminants can get into
the engine.

INTAKE SYSTEM CHANGED BY

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 03 13

AIR FLOW SENSOR (HOT FILM AIR MASS SENSOR)

GENERAL
ASSY
HOUSING
Air outlet Air inlet

EXHAUST I N T A K E
1. Plug-in sensor 7. Hybrid

LUB
2. Cylinder housing 8. Sensor
3. Protection grid 9. Mounting plate
4. Hybrid cover 10. O-ring

COOLING
5. Measuring duct cover 11. Temperature sensor
6. Housing

FUEL
General

CONTROL
Application
The micro-mechanical HFM6 hot-film air mass sensor with flow direction detection by pulsating mass air flow has

SENSOR
been conceived for load recording with internal combusion engines with petrol and diesel fuel injection.
The HFM6 installation is effected in the air intake system between the air filter and the throttle device, in the case of
supercharged engines between the air cleaner and the supercharger. The HFM6 is installed either as a plug-in
sensor in an existing part of the airducting, such as, e.g. the air cleaner housing, or as pre-assembled plug-in sensor
module including cylinder housing.
Depending on the required air flow rate of the combustion engine, various cylinder housing sizes are provided.
The HFM6 also records, in addition to the air mass taken in by the engine, the temperature of the air taken in.
The HFM6 may only be operated with a suitable control unit.

Design and Function

The hot-film air mass sensor is a thermal flowmeter. The sensor element with its temperature sensors and the
heating area is exposed to the air mass flow. Through a metering channel on the plug-in sensor housing a portion of
the air flow from the cylinder housing is routed past a sensor element.
A thin diaphragm is generated on the silicon-based sensor element by means of etching. A heating resistor and
various temperature sensors are laid out on this diaphragm. The heating area is located in the centre of the diaphragm,
which is controlled to an excess temperature using a heating resistor and a temperature sensor. The degree of this
excess

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14 03

temperature depends on the temperature of the air flowing in. Without incoming air flow, the temperature at the
diaphragm edges declines in an approximately linear fashion. Temperature sensors are located symmetrically in
relation to the heating area upstream and downstream of the heating area. When there is no incoming flow, these
sensors indicate the same temperature. With incoming flow, the part of the diaphragm upstream of the heating area
is cooled down due to heat transfer in the boundary layer. The downstream temperature sensor approximately
retains its temperature, due to the air heated up in the heating area.
The temperature sensors indicate a temperature difference which is dependent upon amount and direction of the
incoming flow. The difference signal of the temperature sensor is evaluated as a resistance bridge.
Digital signal processing takes place after digitising the resistor bridge voltage and the intake air temperature sensor
signal. This enables temperature compensation on the basis of the chip temperature and a standardization of the
output characteristic curve.
The plug-in sensor housing contains the electronic module with the evaluation circuit for the sensor.

Intake Air Temperature

The Intake Air Temperature (IAT) sensor is a part of Hot Film Air Mass (HFM) sensor and is a thermistor, a resistor
which changes value based on the temperature of the air entering the engine. Low temperature produces a high
resistance, while high temperature causes a low resistance as the following table.
The ECM provides 5 volts to the IAT sensor through a resistor in the ECM and measures the change in voltage to
determine the IAT. The voltage will be high when the manifold air is cold and low when the air is hot. The ECM knows
the intake IAT by measuring the voltage.
The IAT sensor is also used to control spark timing when the manifold air is cold.

Temp. (°C) Ω)
R min.(Ω Ω)
R nom. (Ω Ω)
R max. (Ω
-40 35,140 39,260 43,760
-20 12,660 13,850 15,120
0 5,119 5,499 5,829
20 2,290 2,420 2,551
40 1,096 1,166 1,238
60 565 609 654
80 312 340 370
100 184 202 222
120 114 127 141
130 91 102 114

Voltage
NTC output voltage (1K Ohm Pull-Up)

A/D Count
Signal(Voltage)

Temperature

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 03 15

GENERAL
Power
supply

ASSY
Intake
air flow
sensor

HOUSING
Air mass signal

EXHAUST I N T A K E
Ground

Air Temp. signal

Intake air tempera-

ture sensor

LUB
HFM sensor

<Circuit Diagram of HFM Sensor>

COOLING
FUEL
CONTROL
SENSOR

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16 03

HFM Sensor - Removal and Installation

HFM Sensor

Preceding Work: Disconnection of negative battery

cable

1. Disconnect the HFM sensor connector.

2. Loosen the clamps on the air cleaner and the turbo
charger and remove the duct.

3. Unscrew the bolts and remove the HFM sensor

assembly.

Installation Notice
Tightening torque 4 ~ 5 Nm

4. Install the reverse order of removal.

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 03 17

INTERCOOLER

GENERAL
The turbo charger is designed to improve the engine power by introducing more air (oxygen) into the engine. However,
the intake air is heated (100 ~ 110°C) during the compression process in turbo charger compressor and the density
is lowered.

ASSY
The intercooler is the device which cools (50 ~ 60°C) the air entering the engine. Cold air has more oxygen
molecules than warm air. Thus cooler air gives more power and better fuel economy.

HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR
1. Intercooler

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18 03

Intercooler - Removal and Installation

1. Disconnect all wiring harnesses and related connectors from the front side of radiator assembly.

Ambient AQS sensor

temperature
Connector
switch

Ambient tem-
Receiver drier perature sensor

2. Remove the front end center member.

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 03 19

3. Remove the hood latch cable and remove the

GENERAL
radiator support upper member.

ASSY
HOUSING
EXHAUST I N T A K E
4. Remove the intercooler inlet hose and outlet hose. Tightening torque 6 ~ 7 Nm

LUB
COOLING
FUEL
CONTROL
SENSOR
5. Unscrew the bolts and remove the intercooler assembly.

6. Install in the reverse order of removal.

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20 03

INTAKE MANIFOLD ASSEMBLY

System Characteristics
1. Shape that delivers the required capacity of compressed air from turbo charger to inlet port
2. Optimized EGR gas mixture in inlet chamber
3. Maximized intake efficiency with helical and tangential inlet port
1) Improving the swirl ratio in low and mid operating range
2) Improving the acceleration/fuel economy and reducing the maintenance in low and mid operating range
4. Integrated inlet port and coolant outlet port

INTAKE SYSTEM CHANGED BY

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 03 21

GENERAL
Special Tools and Equipment
Name and Part Number Application

ASSY
Y99220112B Installation of intake manifold
Intake manifold guide pin

HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

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22 03

Intake Manifold - Removal/Installation

Preceding Work: Disconnection of negative battery
cable

1. Lift up the vehicle and remove the skid plate.

2. Open the coolant reservoir cap and loosen the drain
cock to drain the coolant.

3. Remove the air inlet hose (1) from intake manifold.

4. Loosen the clamp and remove the coolant inlet hose
(2).

5. Remove the coolant inlet port housing.

6. Remove the vacuum hose from EGR valve.
7. Remove the EGR valve mounting bolts and gasket.
Remove the EGR exhaust pipe (primary) mounting
bolts and gasket.

NOTICE
• Replace the pipes (2, 3) at both sides of EGR cooler
(1) and gaskets with new ones.
• Make sure that the convex surface of gasket is fac-
ing to the pressurized direction.

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 03 23

8. Remove the brackets and connectors from top section

GENERAL
of the engine.
1) Vacuum hose bracket in turbo charger
2) Booster pressure sensor

ASSY
3) Main wiring bracket
4) Ground cable bracket
5) Fuel pressure sensor connector

HOUSING
9. Unscrew the bolts and remove the vacuum modulator
bracket.

EXHAUST I N T A K E
Installation Notice
Tightening torque 9.0 Nm

10. Remove the HP pump fuel supply line bolts.

11. Remove the HP pump fuel supply line mounting
bracket.
12. Remove the HP pump fuel return line at fuel filter.

LUB
NOTICE
• Plug the openings of pipes and ports with sealing

COOLING
caps to keep the cleanness of the fuel system.
• Replace the pipes with new one once removed.

FUEL
13. Remove the injector return line at HP pump.

CONTROL
NOTICE
• Be careful not to damage the pipes to HP pump.
• Plug the fuel return port of the HP pump with a seal-

SENSOR
ing cap.

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24 03

14. Remove the intake manifold mounting bolts.

Installation Notice
Tightening torque 25 ± 2.5 Nm

Check the length of the bolts before installation.

M8 x 45: 6EA
M8 x 130: 6EA

15. Lift up the vehicle and remove the propeller shaft

joint bolts.
16. Unscrew the bolt in oil filter and remove the intake
manifold and gasket.

NOTICE
• Replace the gasket with new one.
• Make sure that the residual coolant in intake mani-
fold gets into the inside of inlet port.

17. Install in the reverse order of removal.

NOTICE
• Replace the gasket with new one.
• If replaced only gasket without any other service
operation, completely remove the coolant and
other contaminants from the engine before
installation.

INTAKE SYSTEM CHANGED BY

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EXHAUST SYSTEM
04

TABLE OF CONTENTS
EXHAUST SYSTEM LAYOUT ................................. 2
Components locator ...................................................................2
Exhaust gas flows .....................................................................3
Turbo charger assembly .............................................................5
VGT (Variable Geometry Turbocharger) .................................... 24

EGR VALVE AND VACUUM MODULATOR .......... 38

EGR system ............................................................................ 38
EGR valve and turbo charger actuator control vacuum circuit ... 39

VACUUM MODULATOR ........................................ 42

Composition ............................................................................. 42
Removal and Installation of EGR Valve ..................................... 43
Removal and Installation of vacuum modulator assembly ......... 48
Electrical circuit related to vacuum modulator .......................... 50

EXHAUST SYSTEM AND MUFFLER ................... 54

Muffler ...................................................................................... 54
System overview ...................................................................... 55
 2

Exhaust Manifold
04

Diesel catalytic

ACTYON SM - 2006.03
converter

EXHAUST SYSTEM
To EGR Intake
To turbo- valve
charger manifold

Exhaust
manifold EGR valve
COMPONENTS LOCATOR
EXHAUST SYSTEM LAYOUT

EGR center pipe

EGR Valve and Installation Location

Exhaust Intake
manifold manifold

Intake air
Intake Intake (intercooler)
manifold manifold

CHANGED BY

AFFECTED VIN
EFFECTIVE DATE
EGR pipe (RH)

Diesel catalytic converter → Muffler EGR pipe (LH)

EGR pipe
 04 3

EXHAUST GAS FLOWS

GENERAL
Catalytic Exhaust pipe
converter Muffler

ASSY
A

HOUSING
Atmo-
sphere

EXHAUST I N T A K E
A Exhaust gas

LUB
Turbo charger

COOLING
(turbine side)
EGR booster
vacuum modulator
To turbo

FUEL
charger booster
Turbo charger
booster vacuum
modulator

CONTROL
Turbo charger
EGR valve
booster
Exhaust manifold

SENSOR
Blow-by gas

EGR pipe

Engine
Exhaust Turbo Exhaust Atmo-
-Combustion
Manifold Charger Muffler sphere
Chamber-

Intake
EGR Valve
Manifold

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4 04

Exhaust Manifold
- Removal and Installation
1. Remove the two intake hoses from the turbo charger.

2. Remove the turbo charger assembly (refer to Turbo

Charger section).

3. Remove the #3 pipe of EGR valve from the exhaust

manifold.

Installation Notice

Tightening torque 35 ± 3.5 Nm

• The #3 pipe of EGR valve is exposed to the high

temperature and pressure of exhaust gas. Replace
the gasket and pipe with new ones. Otherwise, it
may cause the leakage of exhaust gas.

4. Unscrew the nuts and remove the exhaust manifold

and gasket.

Installation Notice
Tightening torque 40 ± 4.0 Nm

• Replace the gasket with new one.

5. Install in the reverse order of removal.

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 04 5

TURBO CHARGER ASSEMBLY

GENERAL
The turbo charger is an air pump installed on the intake manifold. It enhances power and increases torque power of
engine to increase the fuel consumption rate. The engine without turbo charger cannot get as much power output as
it inducts air by the means of vacuum being generated from descending strokes of the piston. Therefore, by installing

ASSY
the turbo charger on the intake manifold, it supplies great amounts of air to the cylinder increasing the volume
efficiency and, subsequently, enhances output power.
Also, as the engine’s power enhances, it increases the torque power and improves the fuel consumption rate. The

HOUSING
regular turbo charger operates by utilizing the pressure from the exhaust gas and the other, called Super Charger,
operates by utilizing power from the engine. When the turbo charger is installed, weight of the engine increases by
10 to 15 % whereas the output power increases by 35 to 45 %.

EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
Operating Principle of Turbo
Charger
Turbine

SENSOR
The turbo charger has one shaft where at each ends are Impeller
installed with two turbines having different angles to con-
nect one end of housing to the intake manifold and the Intercooler
other end to the exhaust manifold. As the turbine, at ex-
haust end, is rotated by exhaust gas pressure the impeller,
at intake end, gets rotated to send air around center of Intake Exhaust
the impeller, being circumferentially accelerated by the
centrifugal force, into the diffuser. Intercooler
The air, which has been introduced to the diffuser having coolant
a passage with big surface, transforms its speed energy
into the pressure energy while being supplied to the cyl-
inder improving the volume efficiency. Also, the exhaust
efficiency improves as the exhaust turbine rotates. The
turbo charger is often referred to as the exhaust turbine
turbo charger.
Diffuser: With the meaning of spreading out it is a device that
transforms fluid’s speed energy into the pressure energy by
enlarging the fluid’s passage to slow down the flow.
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6 04

Construction of Turbo Charger

The turbine wheel in turbo charger and compressor wheel are installed at each side of the shaft. It is comprised with
the shaft supporting center housing (supporting the compressor with two float journal bearings), the turbine side
parts of turbine wheel, shroud and turbine housing, and the compressor side parts of compressor wheel, back plate
and compressor housing.
1. The turbine rotates turbine wheel by receiving exhaust gas energy from the engine.
2. The compressor receives torque energy from the turbine and the compressor wheel inducts air to force it inside
of the cylinder.

1. Turbine housing A. Air inlet (from atmosphere)

2. Turbine wheel B. Air flow
3. Compressor housing C. Exhaust gas inlet (from cylinder)
4. Compressor wheel D. Exhaust gas outlet (to atmosphere)
5. Center housing E. Exhaust gas bypass passage
6. Turbo charger booster pressure control valve H. Oil supply opening
7. Control link J. Oil return line
8. Bypass flap

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Impeller

GENERAL
Impeller Turbine
The impeller is wings (wheel) installed on the intake end
and performs the role of pressurizing air into the cylinder. Turbine
shaft

ASSY
HOUSING
Thrust collar Floating bearing

EXHAUST I N T A K E
The radial type has the impeller plate arranged in straight
line at the center of shaft and, compared to the backward Turbine
type, is being widely used as it is simple, easy to manu-
Impeller
facture and appropriate for high speed rotation. As the
impeller rotates in the housing with the diffuser installed
in it, the air receives centrifugal force to be accelerated in
Exhaust gas
the direction of housing’s outer circumference and flows

LUB
into the diffuser.
As surface of the passage increases, air flown into the
diffuser transforms its speed energy into pressure energy

COOLING
and flows into the intake manifold where the pressurized Diffuser
Oil passage
air is supplied to cylinder each time the intake valve of
cylinder opens up. Therefore, the efficiency of compres-
sor is determined by the impeller and diffuser.

FUEL
Turbine

CONTROL
The turbine is wings installed at the exhaust end where, by the pressure of exhaust gas, it rotates the compressor
and performs the role of transforming heat energy of exhaust gas into torque energy. The radial type is used as the
turbine’s wings. Therefore, during operation of the engine, the turbine receives temperature of exhaust gas and it

SENSOR
rotates in high speed, it requires to have sufficient rigidity and heat resisting property.
During operation of the engine, exhaust gas discharged through the exhaust valve of each cylinder makes turbine rotate
by coming in contact with the turbine’s wings from the outer circumference within housing of the turbine and is
exhausted through the exhaust manifold. At the same time, as the impeller is on the same shaft, it rotates.

Floating Bearing
Floating Bearing is a bearing, which supports the turbine shaft that rotates at about 10,000 to 15,000 rpm. It could be
rotated freely between the housing and the shaft as it gets lubricated by oil being supplied from the engine.

NOTICE
• Stopping the engine immediately after driving at high speed stops oil from being supplied to the bearing and
may cause it to get burnt. Therefore, the engine must be stopped after cooling the turbo system by suffi-
ciently idling the engine.

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Booster Pressure Control Valve Unit (Turbo Charger Actuator)

In order to reduce discharging of hazardous exhaust gas and to avoid the engine’s overrun the turbo charger must be
appropriately controlled. The maximum turbo charging pressure must be controlled as excessive increase in the
pressure and power output can cause critical damages to the engine. In order to control these, the booster pressure
control valve is installed on the turbo charger.
The difference of the booster pressure control between the existing IDI engine and DI engine is that in IDI engine,
booster pressure of the intake manifold operates the booster pressure control valve connected directly to the turbo
charger whereas in DI engine, the control is achieved by utilizing vacuum modulator (vacuum from a vacuum pump)
designed to control the booster pressure control valve. It operates booster pressure control valve by supplying
electrical power to the vacuum modulator having the amount of air being flown into the HFM sensor from the engine’s
ECU as the base signal.
Refer to the EGR section in following pages for the function of turbo charger and HFM sensor in exhaust system.

Booster pressure control valve unit and vacuum modulator

Turbo charger booster

Turbo charger booster
vacuum modulator

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Diagnosis and Maintenance for Turbo Charger System

GENERAL
Cautions During Driving Inspection of Turbo Charger

ASSY
The following lists cautions to take during test drive and When problem occurs with the turbo charger, it could
on the turbo charger vehicle, which must be considered cause engine power decline, excessive discharge of
during the operation; exhaust gas, outbreak of abnormal noise and excessive
1. It’s important not to drastically increase the engine consumption of oil.

HOUSING
rpm starting the engine. It could make rotation at 1. Inspection when installed
excessive speed even before the journal bearing is 1) Check the bolts and nuts for looseness or missing
lubricated and when the turbo charger rotates in poor
2) Check the intake and exhaust manifold for

EXHAUST I N T A K E
oil supply condition, it could cause damage of bearing
looseness or damage
seizure within few seconds.
3) Check the oil supply pipe and drain pipe for
2. If the engine is running radically after replacing the
damages
engine oil or oil filter brings poor oil supply condition.
To avoid this, it’s necessary to start off after idling 4) Check the housing for crack and deterioration
the engine for about 1 minute allowing oil to circulate 2. Inspection of turbine in turbo charger
to the turbo charger after the replacement. Remove the exhaust pipe at the opening of the turbine
3. When the engine is stopped abruptly after driving at and check, with a lamp, the existence of interference

LUB
high speed, the turbo charger continues to rotate in of housing and wheel, oil leakage and contamination
condition where the oil pressure is at ‘0’. In such (at blade edge) of foreign materials.
condition, an oil film between the journal bearing and 1) Interference: In case where the oil leak sign exists,

COOLING
the housing shaft journal section gets broken and even the small traces of interferences on the
this causes abrasion of the journal bearing due to turbine wheel mean, most of times, that abrasion
the contact of metal parts. The repeat of such has occurred on the journal bearing. Must inspect
condition significantly reduces life of the turbo charger. after overhauling the turbo charger.

FUEL
Therefore, the engine should be stopped possibly in 2) Oil Leakage: Followings are the reasons for oil
the idle condition. leakage condition;
• Problems in engine: In case where the oil is

CONTROL
NOTICE smeared on inner wall section of the exhaust
• After string for long period of time during winter gas opening.
season or in the low temperature condition where • Problems in turbo charger: In case where the
the fluidity of engine oil declines, the engine, be-
oil is smeared on only at the exhaust gas outlet

SENSOR
fore being started, should be cranked to circulate
oil and must drive after checking the oil pressure section.
is in normal condition by idling the engine for few
minutes.
NOTICE
• Idling for long period of time can cause oil leak-
age to the turbine side due to low pressure of ex-
haust gas and the rotation speed of turbine wheel.
Please note this is not a turbo charger problem.

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10 04

3) Oil Drain Pipe Defect

Inspection of Turbine
In case where oil flow from the turbo charger
sensor housing to the crank case is not smooth Thoroughly check the followings.
would become the reason for leakage as oil builds
up within the center housing. Also, oil thickens
NOTICE
(sludge) at high temperature and becomes the
indirect reason of wheel hub section. In such case, • Must absolutely not operate the turbo charger with
the compressor outlet and inlet opened as it could
clogging and damage of the oil drain pipe and the
damage the turbo charger or be hazardous dur-
pressure of blow-by gas within the crank case ing inspection.
must be inspected.
4) Damages from Foreign Materials 1. Interference: In case where is trace of interference or
When the foreign materials get into the system, smallest damage on the compressor wheel means,
it could induce inner damage as rotating balance most of times, that abrasion has occurred on the
of the turbo charger gets out of alignment. journal bearing. Must inspect after the overhaul.
2. Oil Leakage: The reason for oil leakage at the
compressor section is the air cleaner, clogged by
substances such as dust, causes the compressor
inlet negative pressure;
1) Rotating in high speed at no-load for extended
period of time can cause oil leakage to the
compressor section as oil pressure within the
center housing gets higher than pressure within
the compressor housing.
2) Overuse of engine break (especially in low gear)
in down hill makes significantly low exhaust gas
energy compared to the time where great amount
of air is required during idling conditions of the
engine. Therefore, amount of air in the compressor
inlet increases but the turbo charge pressure is
not high, which makes negative pressure at the
compressor section causing the oil leakage within
the center housing.

NOTICE
• No problem will occur with the turbo charger if
above conditions are found in early stage but oil
leaked over long period of time will solidify at
each section causing to breakout secondary
defects.

3. Damages by foreign materials: In case where the

compressor wheel is damaged by foreign materials
requires having an overhaul. At this time, it’s
necessary to check whether the foreign materials
have contaminated intake/exhaust manifold or inside
of engine.

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GENERAL
Path of Turbo Charger Defect
The following tries to understand the defects that can occur with vehicle installed with the turbo charger and to
manage the reasons of such defects.

ASSY
1. In case where oil pan/oil pipe has been contaminated, oil filter is defected and where
adhesive of gaskets has been contaminated into the oil line.

HOUSING
Contamination of Oil

EXHAUST I N T A K E
Journal Bearing Clogging of Oil
Damage or Wear Passage

Metal Contact Poor Oil Supply

LUB
Shaft Journal Bearing Wear

COOLING
Rotor Wear

FUEL
CONTROL
Interference of
Seal Wear at Seal Wear at Intake Turbine and Com-
Exhaust System System pressor Components

SENSOR
Oil Leakage

Abnormal Noise Lack of Power/Poor

Acceleration (Lack of
Turbo Charged Pressure)

Check Booster Pressure

Check Exhaust Gas Pipes
Control Valve

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2. Oil Pump Defect: Rapid over-loaded driving after replacing oil filter and oil and clogging of
oil line.

Poor Oil Supply

Metal Contact of Shaft /Journal Bearing/

Center Housing Inner Part

Journal Bearing/Center Housing Inner Part

Wear/Seizure

Melt down of Bearing to Turbine Wheel Journal

Rotor Rotational Movement

Seal Wear at Exhaust Seal Wear at Intake Interference of Turbine and

System System Compressor Components

Oil Leakage

Lack of Power/Poor
Abnormal Noise Acceleration (Lack of
Turbo Charged Pressure)

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3. Turbine Side: Inflow of foreign materials from engine

GENERAL
Compressor Side: such as air filter, muffler and nut

Inflow of Foreign Materials

ASSY
HOUSING
Inflow of Foreign Materials Inflow of Foreign Materials
into Turbine into Compressor

EXHAUST I N T A K E
Compressor Wheel Blade
Shaft Wheel Blade Break
Break

Unbalancing Rotor Rotation

LUB
Rotor Bearing Wear

COOLING
Rotor Turning Movement

FUEL
CONTROL
Seal Wear at Exhaust Seal Wear at Intake Interference of Turbine and
System System Compressor Components

SENSOR
Oil Leakage

Lack of Power/Poor
Abnormal Noise Acceleration (Lack of
Turbo Charged Pressure)

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4. Defects caused by reasons other than that of the turbo charger.

Oil Leakage at Turbine

<In case where the scanner <Mechanical

displays as electrical malfunction> Malfunction>
Excessive Engine Wear Excessive Inflow of Blow-By
Gas, Idling at Low Speed,
Clogging of Oil Drain Pipe
Dampness or Poor Connec-
tion of Turbo Charger Actuator
Connecting Vacuum Circuit

Oil Leakage at Turbine Oil Leakage at Seal

Housing Entrance

Detection of DTC Code

Caused By HFM Sensor or
EGR Valve Malfunction
Misunderstanding of Oil Carbonization Caused By
Leakage High Temperature

Vacuum Modulator Power

Control Error for Controlling
No Problems in Turbo Seal Wear
Actuator in Engine ECU
Charger System

Oil Leakage

Oil Leakage at Compressor

Inflow of Dust Increase of Negative Pressure

Increase at Inlet Side

Oil Leak Sign at Compres- Excessive Inflow of Blow-By

sor Inlet and Outlet Gas, No-Load High Speed
Rotation

Misunderstanding of Oil No Problems in Turbo

Leakage Charger System

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GENERAL
How to Diagnose

The followings are cautions to take in handling defects of turbo charger, which must be fully aware of;

Cautions When Examining the Defects:

ASSY
1. After stopping the engine, check whether the bolts on pipe connecting section are loose as well as the connecting
condition of vacuum port and modulator, which is connected to the actuator.
2. During idling of the engine, check for leakage in the connecting section of pipe (hoses and pipes, duct connections,

HOUSING
after the turbo charger) by applying soap water. The leakage condition in the engine block and turbine housing
opening can be determined by the occurrence of abnormal noise of exhaust.
3. By running the engine at idle speed, abnormal vibration and noise can be checked. Immediately stop the engine

EXHAUST I N T A K E
when abnormal vibration and noise is detected and make thorough inspection whether the turbo charger shaft
wheel has any damages as well as checking the condition of connections between pipes.
4. In case where the noise of engine is louder than usual, there is possibility of dampness in the areas related with
air cleaner and engine or engine block and turbo charger. And it could affect the smooth supply of engine oil and
discharge.
5. Check for damp condition in exhaust gas when there is sign of thermal discoloration or discharge of carbon in
connecting area of the duct.
6. When the engine rotates or in case where there is change in noise level, check for clogging of air cleaner or air

LUB
cleaner duct or if there is any significant amount of dust in the compressor housing.
7. During the inspection of center housing, inspect inside of the housing by removing the oil drain pipe to check for
sludge generation and its attachment condition at shaft area or turbine side.

COOLING
8. Inspect or replace the air cleaner when the compressor wheel is damaged by inflow of foreign materials.
9. Inspect both side of the turbo charger wheel after removing inlet and outlet pipe of the turbo charger.
1) Is the rotation smooth when the rotor is rotated by hand?

FUEL
2) Is the movement of bearing normal?
3) Inspect whether there has been any signs of interference between two wheels.

CONTROL
NOTICE
• It’s important not to drive the engine when the intake manifold hose has been removed.

SENSOR

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Diagnosis and Measure

Poor Engine Power or Smoke Discharge

Air Cleaner Contamination Slack between Compres-

NO NO
and Clogging of Oil Pass sor Entrance and Exhaust Leaks at Intake Manifold
Type Air Cleaner Manifold Connection
YES YES YES

Replace Air Cleaner

Element or Oil Pass Type Inspect and Repair
Reconnect Connections
Air Filter Intake Manifold

NO

Poor Rotation or Interfer-

NO Leaks at Turbo Charger NO
Leaks at Exhaust Mani- ence of Turbo Charger
Connecting Flange
fold Components
YES YES

Inspect and Repair Intake Refer to Diagnosis

Manifold Table

NO

Clogging Between Com-

Clogging Between Air NO NO
pressor Exit and Intake Clogging of Engine Muffler
Cleaner and Compressor
Manifold
YES YES YES

Clean or Replace
Clean or Replace Affected Clean or Replace Affected
Affected Compo-
Components Components
nents

NO

Weakness of Engine
Clogging of Engine Intake/ NO Function, Intake/Exhaust
Exhaust Manifold Valve Damage, Timing
Defects of Each Valve
YES YES

Inspect and Repair Inspect and Repair

Related Components Related Components

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Before Diagnosis

GENERAL
The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses
in related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is,
as described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the

ASSY
scan tool or vacuum tester. It is necessary to manually check on the connections if there are any slacks or loose
circuits even if the visual inspection shows vacuum hose as being connected. If there are not any problems then the
next inspection area is the connections of the system connectors. Most problems with the occurrence of system
malfunction are from conditions of vacuum line and connector connections and the causes from the malfunction of

HOUSING
mechanical mechanism is actually very few.
For example, when there are no problems with basic components, let’s assume that there is a vehicle having
vacuum leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. This vehicle,

EXHAUST I N T A K E
due to the driving condition or, according to the circumstances, smog or other conditions, could create customer’s
complaint and by connecting the scanning device could display as the malfunction of the EGR valve’s potentiometer.
As previously explained, this car has a separate controller to control the HUBER EGR and, in accordance with
various input element, the controller controls EGR valve by regulating the force of vacuum being applied to the EGR
valve through PWM control. At this time, the controller has to receive feedback whether the EGR valve operates
correctly according to the value sent to the EGR modulator and this role is performed by the EGR potentiometer
located at top section of the EGR valve.
In other word, the controller sent correct output value to the EGR vacuum modulator but, due to the leakage of

LUB
vacuum, signal of required value can not be received from the EGR potentiometer causing to display as malfunction
of related parts.
As a reference, the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has

COOLING
different shape than the HUBER EGR valve because the EGR valve’s operation signal in the DI engine is performed
by the HFM sensor instead of the EGR potentiometer.
This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air,
comparatively, will be reduced. The DI engine ECU receives feedback signal of change in amount of air being passed

FUEL
through the HFM sensor according to the opening amount of the EGR valve.

CONTROL
SENSOR

HUBER EGR System for IDI Engine

(Including the EGR Valve Potentiometer)

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The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum
modulator, one is same as being the modulator for EGR valve whereas the HUBER EGR system’s the other modu-
lator controls ALDA of injection pump and the DI engine’s the other modulator controls waist gate of the turbo
charger.
This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical
injection system and DI engine is capable of making electronically controlled fuel injection.
In other word, to reduce the amount of the fuel injection in no-load rapid acceleration mode, the IDI engine’s HUBER
EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing nega-
tive pressure to occur in the vacuum modulator to reduce the amount of fuel injection. When DI engine, basing input
signal from the related sensors such as acceleration pedal sensor and engine RPM, recognizes that current mode
is the no-load rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the
injector. Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other
modulator is used to control the booster pressure valve in turbo charger.

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GENERAL
When Engine Exhaust Gas shows White Smog or
Blue Smog

ASSY
Poor Connection between
NO Oil Leak Sign Around NO Clogging of Engine Oil
Compressor Outlet and
Intake Manifold Element
Intake Manifold

HOUSING
YES YES YES

Reconnection Inspect PVC Line Replace Oil Filter

EXHAUST I N T A K E
NO

Clogging or Damage Oil Leakage at Seal

NO NO Engine Malfunction (Ring,
between Air Cleaner and between Turbo Charger
Piston, Valve)
Turbo and Compressor

LUB
YES YES YES

Clean or Replace Affected Repair (overhaul)

COOLING
Refer to Diagnosis Table
Components Engine

FUEL
Excessive Consumption of Engine Oil

CONTROL
Poor Oil Seal at Turbo
Improper Inspection of Air NO Improper Viscosity of NO
Compressor Side (Oil leak
Cleaner Contamination Engine Oil Being Used sign at housing and wheel)

SENSOR
YES YES YES

Replace Air Cleaner Refer to Diagnosis

Replace with Specified Oil
Element Table

NO

Poor Oil Seal at Turbo Oil Leakage at Engine

NO
Turbine Side (trace of leakage Exhaust Manifold (damages
in housing and wheel) to ring, piston and valve)
YES YES

Refer to Diagnosis Table Inspect or Repair Manifold

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Abnormal Noise from Turbo Charger System

Leaks at Pipe and Hose Inflow of Foreign Material

Contamination or Clogging NO NO
Duct Parts between to Compressor Entrance
of Air Cleaner Manifolds of Turbo Charger or Housing
YES YES YES

Inspect and Repair Air

Clean or Replace If Inspect or Replace Cleaner Element and Turbo
required Connections Charger after Removing
Foreign Materials

NO

Poor Rotation of Rotating

Inflow of Foreign Materials NO Inflow of Foreign Materials NO
Turbo Charger Compo-
to Intake Manifold to Muffler
nents and Interference
YES YES YES

Inspect and Repair Air Repair Housing and

Repair Muffler and Turbo
Cleaner Element and Turbo Turbo Charger and
Charger After Removing
Charger after Removing Inspect Normal Opera-
Foreign Materials
Foreign Materials tion for Engine

NO

Check the Interference

between Rotating Turbo
Charger Components and
Housing
YES

Refer to Diagnosis Table

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GENERAL
Poor Rotation of the Turbo Charger

ASSY
Compressor Wheel Turbine Wheel Damages
NO NO Interference of Compres-
Damages By Inflow of By Inflow of Foreign
sor Wheel with Housing
Foreign Material Material

HOUSING
YES YES YES

Fatigue and Wear in

Repair or Replace Air
Repair or Replace Ex- Bearing or Shaft

EXHAUST I N T A K E
Cleaner Element and
haust Manifold Journal (Refer to
Turbo Charger
Diagnosis Table)

NO

Excessive Deposit of
Clogging of Compressor NO Carbon or Combustion NO Gel Type Oil in Center
by Dust Residues Inside of Turbine Housing

LUB
Wheel by Oil Contamination
YES YES YES

COOLING
Repair or Replace Air Repair or Replace Turbo Repair or Replace Engine
Cleaner Element and Charger Oil Filter and Turbo
Turbo Charger Charger

FUEL
Oil Leakage at Turbine in Turbo Charger

CONTROL
Gel Type Oil in Center
Excessive Filling of Oil NO Clogging of Oil Drain NO
Housing or Excessively
When Installing Pipes in Turbo Charger

SENSOR
Contaminated Oil
YES YES YES

Oil Disappears After Clean or Replace Drain Repair or Replace

Combustion Line Engine Oil Filter and
Turbo Charger

NO

Poor Engine Function

Deterioration of Turbo NO
(Too High Blow-by gas
Charger Journal
pressure in crankcase)
YES YES

Refer to Diagnosis Table Inspect PVC Line

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Oil Leakage at Compressor in Turbo Charger

Clogging or Damage of
Contamination of Air NO NO
Too High Oil Viscosity Pipe between Air Cleaner
Cleaner Element
and Turbo Charger
YES YES YES

Replace Damaged
Clean or Replace Air
Replace With Specified Components after
Cleaner Element
Oil Cleaning clogged Area

NO

Looseness in Connection
NO Oil Leakage at Intake NO Clogging of Oil Drain Pipe
between Compressor
Manifold in Turbo Charger System
Outlet and Intake Manifold
YES YES YES

Reconnect After Inspect and Repair Intake Clean Clogged Area

Inspection Manifold After Inspection

NO

Clogging Between Com-

Deterioration or Damage NO NO
pressor Outlet and Intake Clogging of Engine Muffler
to Compressor Wheel
Manifold
YES YES YES

Clean, Repair or Replace

Air Cleaner Element and Refer to Diagnosis Table Inspect PCV Line
Turbo Charger

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GENERAL
Wear in Turbo Charger Inner Diameter and
Shaft Journal

ASSY
Poor Oil Filling When
NO Contamination of Oil Filter NO Lack of Oil in Turbo
Installing or Replacing
Turbo Charger or Use of Low Grade Oil Charger

HOUSING
YES YES YES

Clean or Replace Air

Reinstall While Using
Cleaner Element / Re- Add Oil During Idling

EXHAUST I N T A K E
Specified Oil
place With Specified Oil

NO

Poor Oil Supply by Wear in Journal Section

NO Clogging of Engine Oil NO
Clogging of Oil Supply By Clogging in Center
Pipe in Turbo Charger Filter Housing

LUB
YES YES YES

Clean and Repair Dam- Repair or Replace

COOLING
Replace Oil Filter
aged Components Turbo Charger

NO

FUEL
Poor Function of Engine
Oil Pump

CONTROL
YES

Inspect and Replace If

SENSOR
Required

For other diagnosis, refer to Diagnosis section.

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VGT (VARIABLE GEOMETRY TURBOCHARGER)

Overview
VGT is a certain type of turbocharger system that increases the intake air volume by using the exhaust air flow.
The following chart shows the comparison values between a normal turbocharger and VGT regarding highest speed,
drive-off performance and pass-ahead acceleration.
1. Enhanced highest speed: 4.1% of the highest speed increases compared to normal turbocharger.
2. Enhanced drive-off performance: The time taken to reach from 0 kph to 100 kph decreases 15.1% compared to
normal turbocharger.
3. Enhance pass-ahead performance: This is evaluated by measuring the time taken to reach from 60 kph to 100 kph.
The shorter it is the better performance.

4.1% increase 15.1% decrease

15.1% decrease
Normal turbocharger

Normal turbocharger

Normal turbocharger
VGT

VGT

VGT
Highest speed (kph x 10) Drive-off sec. (0 -> 100 kph) Pass-ahead sec. (60 -> 100 kph)

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Structure

GENERAL
EGR vacuum
modulator
Turbocharger actuator
Vacuum Turbo-

ASSY
pump charger
Turbocharger actuator
Vacuum
modulator vacuum

HOUSING
modulator

Oil supply tube

EXHAUST I N T A K E
EGR pipe

Support
bar

LUB
Instrument panel ECU No.95
Oil return tube (passenger side)
No.63-7.5A

COOLING
Tightening Torque

FUEL
Turbocharger assembly
Turbocharger actuator
Tightening Turbine housing
25 ± 2.5 Nm
torque

CONTROL
Adaptor pipe
Tightening 25 ± 2.5 Nm
torque

SENSOR
Oil supply tube
Upper Compressor housing
connection 18 ± 1.8 Nm

Lower
18 ± 1.8 Nm
connection

Oil return tube

Support bar Upper

connection 10 ± 1.0 Nm
Upper
connection 32 ± 3.2 Nm
Lower
10 ± 1.0 Nm
Lower connection
32 ± 3.2 Nm
connection

CHANGED BY EXHAUST SYSTEM

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Components of VGT

Hollow bolt
Turbocharger
assembly Seal ring

Seal ring

Oil supply tube

Adaptor

Turbo-
charger
actuator

Gasket

Oil return tube

Gasket

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GENERAL
Components

ASSY
HOUSING
Bearing housing and center
housing:

EXHAUST I N T A K E
This encloses the bearing,
seal, oil recirculation path
VGT actuator:
and turbocharger shaft.
This prevent the turbocharged pressure
from increasing over the specified value.
Turbine housing:
This is located on the
exhaust manifold and
encloses the turbine wheel.

Compressor housing:

LUB
This induces the fresh air
to the compressor wheel
and supplies the com-

COOLING
pressed air to the inter-
cooler through the hose.

FUEL
CONTROL
Turbine wheel:
This is rotated by exhaust gas and Unison ring
connected to the compressor wheel Compressor wheel (Impeller):

SENSOR
through turbocharger shaft. This is rotated by turbine wheel con-
nected through turbocharger shaft, and
compresses and draws the fresh air.

Turbocharger shaft:
This is located within
center housing and
connects the turbine
wheel to the com-
pressor wheel.

Floating bearing:
Turbocharger rotates at very high speed (100,000 ~ 150,000 rpm). To prevent the turbocharger from
being damaged, floating bearing is used for this system. This is lubricated by engine oil. If the engine
stops when the turbocharger is still hot, the bearing may be stuck because the oil cannot be supplied.
After high speed driving, run the engine at idle speed until the turbocharger cools down.

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Components
In VGT system, the turbine and compressor are installed on a same shaft. And on the turbine shaft, 11 variable inlet
vanes are installed to change the flow of exhaust gas. Also, the round unison ring is mounted behind vanes to
activate all vanes concurrently. The turbine housing and compressor housing are installed to cover the turbine and
compressor, and the vane control actuator is installed to activate the unison ring towards the turbine housing.

VGT Solenoid Duty control Engine

Unison ring Vane control valve ECU
actuator

Alternator
Turbine
vacuum pump
housing
Compressor
housing Vane control
Low speed
actuator
Turbine Compressor
Unison ring

Variable turbine
inlet vane Vane

Vane arm

Unison ring
The unison ring is designed to be capable to rotate either clockwise or counterclockwise and to connect to the vane
control actuator.

Variable turbine inlet vane

The variable turbine inlet vane is connected through the unison ring and vane arm, 11 vanes are rotated when the
actuator is activated. 11 vanes are used as a passage for the exhaust gas led to the turbine inlet. According to their
rotation, the flow passage area of exhaust gas varies. At low speed, the flow passage is narrowed and the flow speed
of the exhaust gas increases, resulting in increasing the delivery energy of turbine. At high speed, the flow passage
is widened and the much exhaust gas is generated, resulting in considerably increasing the delivery energy of
turbine.

Vane control actuator

The vane control actuator is connected to the VGT solenoid valve duty-controlled by the engine computer (ECU) via
the vacuum hose. Therefore, the duty rate of the solenoid valve is changed by ECU according to the operating
conditions and accordingly the movement of the actuator is controlled.

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Principles

GENERAL
How it works at low speed
Normal turbocharger can’t get the turbo effect because the amount of exhaust gas is not much and the flow speed

ASSY
is slow in a low speed zone, but VGT allows the flow passage of exhaust gas to narrow, resulting in increasing the
flow speed of exhaust gas and running the turbine quickly and powerfully. Therefore, as VGT can inhale more air than
normal turbocharger, it can give the benefit of the increased output even in a low speed zone.

HOUSING
EGR valve
Intercooler

Booster Accelerator pedal signal

EXHAUST I N T A K E
pressure Vehicle speed signal VGT
Clutch signal

Intake air

Coolant
tempera-
Intake air
ture temperature VGT
Target booster pressure modulator
ECU Vane
Feedback VGT (Air mass)
actuator
Engine rpm Duty control

Vacuum
pump

LUB
COOLING
VGT Solenoid Duty control Engine
valve ECU

Alternator

FUEL
vacuum pump
High speed
Vane control
Low speed
actuator

CONTROL
Unison ring

SENSOR
Vane
Low speed
Vane arm

Basic principle at low speed

At low speed, it utilizes the principle of venturi. For example,
when air flows through the venturi tube, the flow speed is faster Flow tube
and the pressure is lower at the point “A”. In this case, if the
inner diameter of venturi is more narrowed, the flow speed is
V1 x A1 = V2 x A2 = Constant
so much faster (refer to the equation).

Venturi tube Venturi tube Venturi tube

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How it works at low speed

In a high speed zone, the amount of exhaust gas increases and it is accompanied with a great force. Therefore, if the
inner diameter of venturi is more widened, the turbine in the turbocharger by the releasing force of abundant exhaust
gas can deliver a more increased energy to the compressor. The output will increase in submission to the increase
of intake air volume.

EGR valve
Intercooler

Booster Accelerator pedal signal

pressure Vehicle speed signal VGT
Clutch signal

Intake air

Coolant
tempera-
Intake air
ture temperature VGT
Target booster pressure modulator
ECU Vane
Feedback VGT (Air mass)
actuator
Engine rpm Duty control

Vacuum
pump

VGT Solenoid Duty control Engine

valve ECU

Alternator
vacuum pump
High speed
Vane control
High speed
actuator

Unison ring

Vane Low speed

Vane arm

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Controlling VGT system

GENERAL
The VGT control system checks the engine revolution, accelerator pedal value, atmospheric pressure, booster
pressure, water temperature, intake air temperature, vehicle speed and clutch switch signal to determine the driving
conditions of a vehicle.

ASSY
The booster pressure map that is targeted on according to the engine revolution and fuel injection volume is deter-
mined inside of ECU. The ECU drives the vane control actuator to control the booster pressure, by controlling the

HOUSING
solenoid valve to 300 Hz of frequency and the duty value. This helps to maintain the engine at its optimum condition.

Take a note that the booster pressure sensor is adopted, which is designed to perform the feedback control for
matching the booster pressure targeted by ECU by measuring the booster pressure actually. The feedback control

EXHAUST I N T A K E
allows more accurate controlling.

8 Conditions for inhibiting VGT operation

1. If the engine speed is less than 700 rpm
2. If the coolant temperature is below approx. 0?
3. If any part related to the EGR is defective

LUB
4. If the VGT actuator is defective
5. If the booster pressure sensor is defective

COOLING
6. If the mass flow sensor is defective
7. If the throttle flap is defective
8. If the accelerator pedal sensor is defective
If any of above conditions is met, ECU will not control the VGT system.

FUEL
CONTROL
SENSOR

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Notes and Check for VGT

Notes When Handling VGT

1. The turbocharger is sensitive to excessive vibration

coming from external impact. When exposed to
excessive impact or vibration, the inside mechanism
may be damaged even though the outside is intact.

2. The turbocharger should be kept horizontally. If there is much engine oil in the turbocharger and it is kept
vertically with the turbine housing downward, the engine oil may be provided to variable mechanism assembled
towards the turbine housing, which may lead to a malfunction of the variable mechanism.

3. Never re-adjust the adjusting screw marked with yellow

paint or the axial end of actuator. Renew them if you
found looseness of the screw or actuator axle, because
they are shipped after precisely adjusting from the
factory.

4. Do not move or assemble the actuator axle by grasping

it in hands. The actuator axle may be deformed, which
affects the precisely adjusted value.

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5. After installing to the engine, replenish a small amount

GENERAL
of clean engine oil to the inlet before connecting the
oil inlet pipe of the turbocharger.
6. Do not let any metal debris enter when installing to
the engine.

ASSY
7. The engine oil may be provided to the compressor
housing if you rapidly operate the turbocharger with
excessive revolutions immediately after installing to

HOUSING
the engine.
1) Do not raise the engine rpm rapidly after starting
the engine.

EXHAUST I N T A K E
2) Do not raise the engine rpm rapidly after renewing
the engine oil and filter element.
3) Do not stop the turbocharger rapidly after operating
at high engine speed.

Check and Service

LUB
The turbocharger is rarely out of order or damaged unless the engine is operated in abnormal conditions. Therefore,
it is not necessary to additionally check the turbocharger according to mileage or operation hours. It is sufficient to
simply maintain or service the engine thoroughly.

COOLING
The following symptoms occur if there is a fault in the turbocharger:
1. reduced engine output
2. noisy engine operation

FUEL
3. excessive engine oil consumption
4. excessive exhaust gas emitting

CONTROL
The symptoms may be due to a fault of the engine, not the turbocharger. In most cases, you can check the cause
of the fault visually before removing the turbocharger from the engine.

SENSOR
Check Procedures
1. Firstly, check conditions of the engine because the fault may be due to the engine, not the turbocharger.
2. Then, check conditions of the turbocharger as follows:
1) whether the compressor is damaged by metal debris or foreign materials.
2) whether the turbine is damaged by metal debris or foreign materials.
3) whether there is no contact between the wheel and the housing (check the bearing for damage).
4) whether there is damages or influences by hot temperature.

Diagnosis and Servicing

1. Operation conditions of actuator’s diaphragm: It is impossible to control the turbocharger when the operation is
poor.
2. Leaking of the turbocharger housing: More engine oil is consumed when leaking.
3. Damage on the turbocharger bearing: Noise can be heard during the turbocharger is operating (The whole
turbocharger may be damaged when the bearing is damaged).

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Removal and Installation

Basically, the turbocharger should be serviced at Ssangyong Authorized Service Center.
When eliminating the carbon deposit from the turbine wheel during the service procedure, use only soft brush or
solvent other than sand paper or metallic tools.

Adaptor pipe

Oil supply tube

Turbocharger
pressure regulator

Vacuum hose

Bolt

Support bar

Oil return pipe

Cautions When Removing/Installing

1. Use only the turbocharger with same specifications.

2. Replace the gasket and sealing with new ones once removed.
3. Tighten the fasteners with specified tightening torque.
4. Change the engine oil before starting the engine.
5. If suspected, check the oil supply pressure.
6. Check if the turbine nozzle actuator operates properly.

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GENERAL
Removal and Installation of Turbocharger
Preceding Work: 1. Remove the negative battery cable.
2. Drain the engine oil by removing the drain plug of the oil pan.

ASSY
1. Remove the intake hose assembly by removing the clamp on the inlet hose of of the air cleaner.

A. Hose to oil separator

HOUSING
EXHAUST I N T A K E
B.HFM sensor connector

LUB
COOLING
FUEL
2. Remove the intercooler hose of turbocharger.

CONTROL
A.Turbocharger connection
Tightening torque 6 ~ 7 Nm

SENSOR

B.Connecting section of the intercooler side.

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3. Disconnect the vacuum hose from the turbocharger.

4. Remove two mounting nuts on the exhaust pipe

of the turbocharger.
Upper

Tightening torque
25 ± 2.5 Nm
Vacuum hose
Lower Exhaust pipe

Tightening torque
25 ± 2.5 Nm

5. Remove the support bar mounting bolt and nut 6. Separate the hook for engine ground cable and remove
from the turbocharger to remove the support bar. the lower mounting bolts from the oil return pipe.

Nut
Tightening torque Hook
23 ± 2.3 Nm

Bolt
Tightening torque
10 ± 1.0 Nm

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7. Remove the hollow bolt from the oil supply pipe of the turbocharger and remove the pipe.

GENERAL
Upper Side Lower Side

ASSY
HOUSING
EXHAUST I N T A K E
Tightening torque Tightening torque
15 ± 1.5 Nm 23 ± 2.3 Nm

Tightening torque
8. Remove three mounting 25 ± 2.5 Nm
nuts from the exhaust
manifold of turbocharger.

LUB
COOLING
FUEL
Tightening torque
25 ± 2.5 Nm

CONTROL
SENSOR
9. Remove the turbocharger assembly.

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EGR VALVE AND VACUUM MODULATOR

EGR SYSTEM
General Information
Various sensor
EGR system controls the opening value of EGR valve by Signals
transmitting electrical signal (PWM control) from the en-
Vacuum
gine ECU to vacuum modulator. Also, the engine ECU modulator
receives the feedback signals of the amount of air flowing
through the HFM sensor. Air filter EGR
Vacuum pump
valve

HFM sensor

1. EGR valve
2. Vacuum modulator
3. Vacuum pump
4. EGR center pipe (EGR cooler)
5. Intake manifold

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EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM

GENERAL
CIRCUIT
Vacuum Modulator

ASSY
The biggest difference between the vacuum circuit and layout of the HUBER EGR system after K2004 has been
introduced is the location of the vacuum modulator for EGR valve control and the function of the other modulator. In
case of EGR equipped vehicle (IDI Engine), it performs the role of controlling the PLA of injection pump whereas, in

HOUSING
DI engine, it controls the turbo charger actuator.

DI engine vacuum modulator

EXHAUST I N T A K E
1. Turbo charger booster vacuum modulator
To EGR valve From vacuum pump
2. EGR valve vacuum modulator

To Turbo Charger Actuator (Gray)

To turbo charger Vacuum pump
To EGR Valve (Black) actuator

LUB
COOLING
FUEL
CONTROL
SENSOR

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Vacuum Modulator and Vacuum Hose

Below figures illustrate vacuum hoses and related parts of EGR or turbo where wrong or poor connection of vacuum
hose would display condition of engine irregularity and defect diagnostic codes on the scan tool.

Related with EGR valve

From vacuum pump

EGR valve

Vacuum modulator for

EGR valve control

Related with turbo charger actuator

Turbo charger pressure valve

Vacuum modulator for turbo From vacuum pump

charger booster control

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EGR System Diagram

GENERAL
Intercooler

ASSY
Intake
Exhaust manifold

HOUSING
manifold EGR
valve Vacuum
Regulated Modulator
vacuum
pump
pressure

EXHAUST I N T A K E
Duty
control

Feedback EGR Air intake signal

(Air Mass) ECU (for EGR feed-
back control)
Improved target EGR

Pedal RPM Turbo charger

signal signal

LUB
: Intake air : Exhaust gas

COOLING
EGR valve
EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU

FUEL
signals.
1. EGR valve opening point : -220~250 mmHg

CONTROL
EGR modulator
According to ECU signals, the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated
by vacuum pump with PWM type controls.

SENSOR
Main relay

Engine ECU

Vacuum modulator for Vacuum modulator for

VGT turbocharger EGR valve
actuator
Engine extension wiring

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VACUUM MODULATOR

COMPOSITION
Layout

EGR valve

Turbocharger
actuator

Vacuum pump hose

Vacuum pump

Turbocharger vacuum modulator

EGR vacuum modulator

Vacuum Modulator for VGT Vacuum Modulator for EGR Valve

Turbocharger Actuator Control

IP internal fuse Engine ECU

IP internal fuse Engine ECU (RH) No.63-7.5A No. 96
(RH) No.63-7.5A No. 95

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REMOVAL AND INSTALLATION OF EGR VALVE

GENERAL
EGR Valve and Pipe
1. Remove the inlet hose to the intake manifold and disconnect the vacuum hose of the EGR valve.

ASSY
Inlet hose to Intake Manifold Vacuum Hose to EGR Valve

HOUSING
EXHAUST I N T A K E
Tightening torque
6 ~ 7 Nm

LUB
2. Remove the mounting bolt/nut to remove the left pipe of the EGR valve and unscrew four hexagon bolts to remove
the EGR valve assembly.

COOLING
EGR Valve Pipe (LH) EGR Valve Assembly

Tightening torque (bolt)

10 ± 1.0 Nm

FUEL
CONTROL
SENSOR
Tightening torque (bolt) Tightening torque (hexagon bolt)
10 ± 1.0 Nm 10 ± 1.0 Nm

3. Remove the right pipe of the EGR valve and remove the center pipe.

EGR Valve Pipe (RH) EGR Valve Pipe (Center)

Tightening torque (bolt) Tightening torque (M8 X 30)

10 ± 1.0 Nm 25 ± 2.5 Nm

Tightening torque (nut) Tightening torque (M8 X 25)

35 ± 3.5 Nm 25 ± 2.5 Nm

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4. Install in the reverse order of removal.

NOTICE
1. Observe the tightening torque of the bolts and nuts when installing pipes.
2. Replace the gaskets of the pipes with new ones. The protruding side should face to pressurized section.

EGR RH Pipe and Gasket EGR LH Pipe and Gasket

Center pipe bolt (2 EA) Intake pipe bolt (4 EA)

(M6 X 16: 10 ± 1.0 Nm) (M6 X 16: 10 ± 1.0 Nm)

Exhaust manifold nut (2 EA)

(M8: 35 ± 3.5 Nm)

* M8 mounting nut should be replaced with new one.

EGR valve

Center Pipe EGR Valve

Center pipe upper bolt (2 EA) EGr valve mounting bolt (4 EA)
(M8 X 25: 25 ± 2.5 Nm) (M6 X 25: 10 ± 1.0 Nm)

Center pipe lower bolt (2 EA) LH pipe mounting bolt (2 EA)

(M8 X 25: 25 ± 2.5 Nm) (M6 X 16: 10 ± 1.0 Nm)

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Inspection for EGR System

GENERAL
If the EGR system is malfunctioning, the engine power may be decreased or the exhaust gas may be increased. If
these happen, troubleshoot the system according to the following procedures.

ASSY
1. Inspection for EGR vacuum system
Check the EGR vacuum system (engine vacuum pump - vacuum modulator for controlling EGR valve - EGR valve) for

HOUSING
malfunction. Specifically, check the vacuum hose, connections, kinked hose and leaks due to interference with
surrounding components. Also check the EGR vacuum modulator's wiring connector. Make sure that the vacuum
system source functions properly by checking the engine vacuum pump for leakage.

EXHAUST I N T A K E
EGR valve
Main vacuum when
idling: 690 mmHg

LUB
Vacuum modulator
for turbocharger Brake booster
actuator

COOLING
IWE locking
hub

FUEL
Vacuum modulator
for EGR valve

CONTROL
2. EGR related DTC check using SCAN-100
Connect the SCAN-100 to the CAN module and check if

SENSOR
there is any DTC related to EGR.
If DTC is appeared, it may be due to the vacuum system.
Therefore, check the EGR system again.

DTC Related to EGR System

P0400 Faulty EGR valve control

P1405 Short circuit to EGR vacuum

modulator (GND)

P1406 Short circuit to EGR vacuum

modulator (B+)

All DTCs are related to EGR valve vacuum modulator.

Therefore, check the power supply and ground con-
dition by performing the following electrical check
for EGR valve vacuum modulator.

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3. Electrical check for EGR valve vacuum modulator

The EGR valve vacuum modulator is supplied with power from the main relay and fuse No. 63 (7.5 A) in the interior
fuse box which is located in the instrument panel (RH). Therefore, those relays and fuses should be checked first.
The vacuum modulator for the VGT turbocharger actuator is installed on the top of the vacuum modulator for EGR
valve. Both are supplied with the same power and controlled (duty cycle) by engine ECU. The following is the
procedure for checking the power supplied to the vacuum modulator.

IP Interior Fuse Box (Passenger Side) Vacuum Modulator

Engine ECU
main relay Vacuum modulator for VGT
turbocharger actuator
VGT & EGR vacuum
modulators, HFM

Vacuum modulator
for EGR valve

HP pumpIMV
Hazard Connector
warning lamp

Connector Installtion of multimeter

Terminal No. 1

IP interior fuse (RH) Engine ECU

No.63-7.5A No. 96

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GENERAL
4. EGR valve check
If there is no problem found so far, check the EGR valve as a unit.
The EGR valve is working as a passage for exhaust gas. It may not operate due to the contamination by the carbon
or other foreign materials.

ASSY
Check the unit according to the following procedures.

HOUSING
1. Remove the intake inlet hose. 2. Connect the vacuum tester to EGR valve.

EXHAUST I N T A K E
LUB
COOLING
3. Check if EGR valve starts to open when the vacuum 4. Check the conditions of EGR valve.
gauge indicates approx. 220 ~ 250 mmHg.

If the valve is severely contaminated, completely wipe FUEL

CONTROL
SENSOR
it out with soft cloth. Be careful not to damage it.

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REMOVAL AND INSTALLATION OF VACUUM MODULATOR ASSEMBLY

Removal and Installation
1. Separate the vacuum hose to EGR valve (1), the vacuum hose to turbocharger (2) and the vacuum hose to
vacuum pump (3) in turn.

EGR valve vacuum hose Vacuum pump hose

Vacuum hose for

turbocharger actuator

Brake
booster

IWE locking hub

2. Disconnect the vacuum modulator connectors 3. Unscrew the mounting bolts and remove the
to turbocharger (A) and EGR valve (B). vacuum modulators.

Tightening torque
10 ± 1.0 Nm

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GENERAL
4. Unscrew the mounting bolts and remove the
vacuum modulator bracket.

ASSY
HOUSING
EXHAUST I N T A K E
Vacuum modulator

5. Install in the reverse order of removal.

LUB
COOLING
FUEL
Components

Vacuum modulator for VGT

Bracket turbocharger actuator

CONTROL
Port to VGT turbocharger actuator

SENSOR
Port to vacuum pump

IP internal fuse (RH) Engine ECU

No.63-7.5A No. 95
Port to EGR valve

Vacuum modulator for EGR valve

IP internal fuse (RH) Engine ECU

No.63-7.5A No. 96

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ELECTRICAL CIRCUIT RELATED TO VACUUM MODULATOR

Main relay

Engine ECU

Vacuum modulator Vacuum

for VGT turbo- modulator for
charger actuator EGR valve

Engine extension wiring

IP Fuse Box (Passenger Side) Engine Main Relay & Fuse No. 63

Engine main relay

Fuse No. 63 (7.5A)

Fuse No. 63 (7.5A)

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Operation Principle of Vacuum Modulator

GENERAL
Vacuum
pump

ASSY
Output vacuum

HOUSING
ATM

Plunger

EXHAUST I N T A K E
Connector

LUB
COOLING
Vacuum
control
Diaphragm

FUEL
Seat assembly
Atmospheric pressure Spring
Plunger

CONTROL
SENSOR
Air flow

During duty increase (B) During duty reduction (C)

Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover
and magnetic force (II) in plunger.

According to ECU signals, the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900
± 20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.

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Operating principle: Balance between original vacuum pressure and magnetic forcs (see aboe figure)
1. Normal state (Fig. A): Original vacuum and seat section, 3 stoppers keep sealing
2. Duty up state (Fig. B): Original vacuum pressure is connected to inside of diaphragm chamber
3. Duty down state (Fig. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate
the pressure.

Floating plunger Stroke

(mm)
Max. Distance
DUTY 50% 1mm

Output C/V

Operating principles when duty is applied from 0 to 50 %

Vacuum consumption: Compared to 50 % of duty, ON/OFF periods are most unstable and
vacuum consumption is most high.

Flowing
volume

Output characteristics
Output vacuum (-mmHg)

Up

Down

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Operating conditions

GENERAL
1. Engine is running
2. Engine RPM is within a specified range. (EGR OFF under high RPM range)
3. Engine torque is within a specified range. (EGR OFF under high torque range)

ASSY
4. Vehicle speed is within a specified range. (EGR OFF under high speed range)
5. Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure)
6. Coolant temperature is within a specified range. (EGR OFF under high or low temperature)

HOUSING
7. EGR OFF under extended period of idling.

EXHAUST I N T A K E
Control logic
1. Main map: EGR volume is controlled based on intake air volume
2. Auxiliary map
1) Coolant temperature (Coolant temperature sensor)
2) Engine rpm (Crankshaft position sensor)
3) Engine load (TPS): Detection of sharp acceleration
4) Intake air temperature (HFM): Decreases when over 60°C

LUB
5) Atmospheric pressure (Barometric sensor): Compensation of altitude
3. Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR
volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings.

COOLING
Shut-off conditions

FUEL
1. Engine rpm: over 2,950 rpm
2. Vehicle speed: over 105 km/h
3. Coolant temperature: over 100°C or below 10°C

CONTROL
4. Idle period: over 50 seconds

SENSOR

CHANGED BY EXHAUST SYSTEM

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AFFECTED VIN
54 04

EXHAUST SYSTEM AND MUFFLER

Tail pipe

Muffler

#1 Pipe
DOC (Diesel Oxidation Catalyst)

MUFFLER
The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by
eliminating the flowing resistance from the exhaust gas.
The important elements of the muffler are volume, construction and location.

EXHAUST SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 04 55

SYSTEM OVERVIEW

GENERAL
Exhaust System Muffler
Check the complete exhaust system and the nearby Aside from the exhaust manifold connection, the ex-

ASSY
body areas and trunk lid for broken, damaged, missing haust system uses a flange and seal joint design rather
or mispositioned parts, open seams, holes, loose than a slip joint coupling design with clamp and U-bolts.
connections, or other deterioration which could permit If hole, open seams, or any deterioration is discovered

HOUSING
exhaust fumes to seep into the trunk may be an indica- upon inspection of the front muffler and pipe assembly,
tion of a problem in one of these areas. Any defects the complete assembly should be replaced. The same
should be corrected immediately. procedure is applicable to the rear muffler assembly.
Heat shields for the front and rear muffler assembly and

EXHAUST I N T A K E
NOTICE catalytic converter protect the vehicle and the environ-
ment from the high temperatures that the exhaust sys-
• When you are inspecting or replacing exhaust
system components, make sure there is adequate tem develops.
clearance from all points on the underbody to
avoid possible overheating of the floor panel and
possible damage to the passenger compartment
insulation and trim materials.
Heat Shield
The heat shield protects the vehicle and components

LUB
from the high heat generated from the exhaust system.
DOC (Diesel Oxidation Catalyst) In this vehicle, the heat shield to block the heat from
DOC is installed to the underbody, and the heat shield
DOC (Diesel Oxidation Catalyst) is the purification de-

COOLING
to block the heat from the rear muffler is installed to the
vice to reduce the toxic emissions from the exhaust gas underbody between the fuel tank and the rear muffler.
from the engine. By using the chemical reaction, the
amount of toxic gas such as NOx can be reduced.

FUEL
Hanger
NOTICE
The hanger is to support the components.
• To prevent damage of DOC, never contact the lift
pad when lifting up the vehicle. If the ganger is not properly installed, it may cause the

CONTROL
vibration that is very difficult to diagnose. Therefore, in-
stall the hanger to the correct location so that the ex-
haust system cannot contact to the underbody and other
components.

SENSOR

CHANGED BY EXHAUST SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
56 04

DOC (Diesel Oxidation Catalyst)

System and principle Catalytic converter structure
Oxidation catalytic technology for diesel engine is basi- The Catalytic converter of monolith type consists of 2
cally the same with it of gasoline engine used before walled metal bodies which is made of Cordierite.
development of 3 primary catalyst (2 primary catalyst), The principal element of converter consists of the mate-
and its effect and performance were already proved. rials like Alumina or oxidized Serume in order to apply
DOC (Diesel Oxidation Catalyst) reduces HO and CO to Ceramic Monolith. Washer coat operates first, and
contained exhaust gas over 80 %, and removes SOF catalytic metal elements (Pt, Pd, Ph) operates to washer
(Soluble Organic Fraction) over 50 ~ 80 %, but because coat next.
its portion in total PM is low, it reduces approx, 20 ~ 40 Monolith type is lighter than other types, easy to manu-
% of TPM (Total Particulate Material). facture and quickly approaches to proper temperature.
Because of low reducing rate for PM of DOC, in order to Washer coat is used to make a contact surface with
guarantee safety rate of PM regulation, this technology exhaust gas bigger by adhering closely to small holes
is being used mainly. And it should keep over 80% of of inner layer.
PM reducing rate, and at present it plays a role as a
If a lead compound or phosphorus adheres to the sur-
transition stage.
face and the temperature rises, its surface is decreased.
And also it reduces diesel odor and black smoke, plati-
The total area of general monolith converter is about
num or palladium are being used as a catalyst.
45,000 ~ 500,000 ft3. (10 times of a football field)
On the other hand, it is a problem that it makes the
Generally Alumina (AL2O3) is used as a raw material
reaction of oxidation, which SO2 produce SO3 and H2
and its 7 phases of gamma, delta, theta have big areas
SO4 by reacting to oxygen in exhaust gas, if tempera-
and high stability for the temperature, and nowadays
ture of exhaust gas becomes over 300°C, and this pro-
gamma Alumina is used usually.
duced gas is very harmful to human body. To prevent is,
previously it is requested that the sulfur content rate of
fuel should be below 0.05 %, and in the future it is being
expected to keep it below 0.01 %.
Cover
Insulation Upper part of
Mat converter

Plate

Lower part of Monolith

converter catalyst

Inlet gas Outlet gas

EXHAUST SYSTEM CHANGED BY

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AFFECTED VIN
 04 57

Catalytic converter and temperature

GENERAL
Catalytic converter has the normal function of purification
at a range of the temperature. Because it has a weak
point of decreasing of the purification rate in the condition

ASSY
of continuous high temperature, it should keep the tem-
perature range of 400 to 500°C for normal condition. HC
purification rate becomes better according to the increase
of temperature in the normal range of temperature. CO

HOUSING
purification rate becomes the best near the temperature
of 450°C, and NOx does so near the temperature of 400
to 500°C.

EXHAUST I N T A K E
Purification of catalytic converter
1. Adhesion of soluble organic fraction (SOF) below 180°C
2. Purification of soluble organic fraction (SOF) over 180°C

Chemical reaction formula

LUB
1. SOF (HC) + O2 .......... O2 +H2O
2. 2CO + O2 .................. 2CO2
3. 2C2H6 + 7O2 ............. 4CO2 + 6H2O

COOLING
FUEL
CONTROL
Aldehide

Aromatic
HC

6. Oxygen adheres to catalytic material : below 180°C SENSOR

Catalytic Material

Catalytic Material

CHANGED BY EXHAUST SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
58 04

5. Catalytic material supplies each CO and HC with O2

for their oxidation : above 180°C

Catalytic Material Catalytic Material

6. Catalytic material conversion process by DOC

PAH (Aromatic HC)

Catalyzer

Method for reduction of NOx

NOx is generated a great deal in case that combustion
temperature and excess air factor are high. EGR valve
can decrease NOx (30 to 35% decrease) by making tem-
perature of combustion chamber fall by means of exhaust
gas re-circulation.

EXHAUST SYSTEM CHANGED BY

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AFFECTED VIN
 04 59

MEMO

GENERAL
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ASSY
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HOUSING
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EXHAUST I N T A K E
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LUB
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COOLING
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FUEL
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CONTROL
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SENSOR
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AFFECTED VIN
60 04

Exhaust Pipe
- Removal and Installation
1. Remove the upper bolts at turbo charger.

NOTICE
• Use the universal type wrench.

2. No.1 Exhaust Pipe

A. Unscrew two mounting bolts/nuts from the upper side
(turbocharger).

Turbocharger

Diesel
catalytic
3. Diesel catalytic converter (Rear) converter
A. Remove the pipe mounting rubber using a screwdriver.

EXHAUST SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 04 61

GENERAL
ASSY
B. Remove two lower mounting bolts/nuts and the gasket.

HOUSING
EXHAUST I N T A K E
4. No.2 Exhaust Pipe and Muffler

LUB
• Remove two mounting bolts/nuts from the muffler
side and remove the pipe mounting rubber using a
screwdriver.

5. No.3 Exhaust Pipe and Muffler COOLING

FUEL
CONTROL
SENSOR

• Remove the pipe mounting rubber using a screwdriver.

CHANGED BY EXHAUST SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
 MEMO
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.................................................................................................................................................................................................................................................................................................................................................................................................................................................................
LUBRICATION SYSTEM
05

TABLE OF CONTENTS
LUBRICATION SYSTEM ......................................... 2
Layout and overview ...................................................................2
Lubrication system layout ..........................................................3
Lubrication diagram .................................................................... 4
Specifications ............................................................................5
Engine oil change ......................................................................9
Oil spray nozzle ....................................................................... 13
Oil pan assembly ..................................................................... 14
Removal and installation of oil pan and oil pump ...................... 15

TROUBLE DIAGNOSIS ......................................... 19

 2

PCV Oil Separator Cylinder Head Cover Oil pressure Warning Lamp
(Cluster)
Cylinder head cover (oil + gas)
05

ACTYON SM - 2006.03
LUBRICATION SYSTEM
Blow-by gas
(air duct hose)
Inlet port

Oil (oil
Lubrication System

gauge pipe)
The first separation will happen when blow-
LAYOUT AND OVERVIEW

by gas passes through baffle plates in cylin- Cluster

der head cover. Then oil and gas will be sepa-
rated due to cyclone effect after entering the
LUBRICATION SYSTEM

oil separator inlet port. Separated oil returns

to oil pan via oil drain port and the gas will be
burnt again after entering the combustion
chamber through air duct hose via PCV valve
that opens/closes due to pressure differences
between the intake side and crankcase.

Oil dipstick gauge

Oil Pan and Baffle Plate Oil Filter & Oil Cooler
Oil Strainer
(Integrated Type)

Oil Oil

CHANGED BY
cooler filter

AFFECTED VIN
EFFECTIVE DATE
 05 3

LUBRICATION SYSTEM LAYOUT

GENERAL
Main oil gallery: φ 16
Hole to cylinder head: φ 9

ASSY
Main bearing hole: φ 7
Chain and injection pump: φ 7
Return hole: φ 14
Cylinder Head Chain nozzle: φ 1

HOUSING
HP pump bearing: φ 6

EXHAUST I N T A K E
LUB
COOLING
Cylinder Block

FUEL
CONTROL
SENSOR

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
4 05

LUBRICATION DIAGRAM

Camshaft
Chain lubrication HLA device bearing Vacuum pump

Chain tensioner
check valve

Return check valve

to cylinder head Oil injection
Thrust Turbo Connecting Main
nozzle charger bearing
bearing rod bearing

Filter by-pass valve

Oil
filter
Contaminated By-pass
oil gallery throttle

Clean oil gallery

Oil pump and strainer Relief

valve
Oil cooler

Oil filter

Oil pan

1. Opening pressure of by-pass valve in oil filter: 3 ± 0.4 bar

2. To prevent instant oil shortage after stopping the engine, the return check valve is installed in oil supply line of
cylinder head.

LUBRICATION SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 05 5

SPECIFICATIONS

GENERAL
Engine oil Specification Approved by MB Sheet 229.1 or 229.3
Viscosity: See MB Sheet 224.1

ASSY
Capacity 6.8 ~ 8.3 liter
Service interval Initial change: 5,000 km, Change every 10,000 km or
12 months (Frequently check the oil level and add if needed.
And, every 5,000 km or 6 months under severe conditions)

HOUSING
Engine oil filter Same interval with engine oil
Oil relief valve opening pressure 5.8 ± 0.3 bar

EXHAUST I N T A K E
Severe Condition:
1. When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
2. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when
most trips are less than 16 km)
3. When operating in dusty, sandy and salty areas
4. In hilly or moutainous terrain
5. When doing frequent trailer towing

LUB
Oil Pressure Switch

COOLING
1. Operating temperature: -40 ~ 140°C
2. Operating pressure: 0.3 ~ 0.55 bar
3. Permissible pressure: 10 bar

FUEL
CONTROL
SENSOR

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
6 05

Oil Pump
Relief Valve Opening
Oil Pressure

MB SHEET
229.1/3 5.8 ± 0.3 bar
SAE 10W 40, 5W 40

1. Enlarged pump capacity: Width of tooth (pump gear):

33 mm
2. Increased number of teeth (sprocket): 26

Oil Cooler
1. Oil cooler mounting bolt: M6 x 16: 4

Installation Notice
Tightening torque 10 Nm

2. Replace two oil cooler gaskets with new ones when

the oil cooler has been removed.

LUBRICATION SYSTEM CHANGED BY

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AFFECTED VIN
 05 7

Blow-by Gas Reduction Device

GENERAL
ASSY
Oil dipstick tube

HOUSING
PCV valve + oil

EXHAUST I N T A K E
separator

to air duct
hose

LUB
COOLING
Cylinder Head Cover

FUEL
Blow-by gas inlet port Baffle plate

CONTROL
SENSOR
U-type oil
drain pipe

Baffle plate assembly: The baffle plates in cylinder head cover separates oil and gas from blow-by gas, and
controls the blow-by gas speed to send only gas to separator.

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
8 05

Oil Separator
Inlet port (oil + gas)
(connected to cylinder head
cover through blow-by hose)

Outlet port (gas only)

(connected to air duct hose)

Oil drain (oil only)

(connected to oil pan through
oil dipstick tube)

The first separation will happen when blow-by gas passes through baffle plates in cylinder head cover; then oil and
gas will be separated due to cyclone effect after entering the oil separator inlet port. Separated oil returns to oil pan
via oil drain port and the gas will be burnt again after entering the combustion chamber through air duct hose via PCV
valve that opens/closes due to pressure differences between the intake side and crankcase.

Engine Oil Pressure Check

Check the oil level and quality before checking the oil
pressure.
1. Drain the engine oil.
2. Disconnect the oil pressure switch connector and
remove the switch.
3. Install the oil pressure gauge into the switch hole. Start
the engine and let it run until the coolant temperature
reaches at normal operating temperature (80 ~ 90°C).
4. Raise the engine speed by 2000 rpm and measure
the engine oil pressure.

Specified oil pressure 2.5 ~ 3.0 kg/cm2

(2000 rpm)

5. Install the switch and engage the connector.

NOTICE
• Apply the Loctite onto the thread of the switch and
check for oil leaks.

Tightening torque 120 ~ 160 kg/cm2

LUBRICATION SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 05 9

ENGINE OIL CHANGE

GENERAL
Change interval: Initial change 5,000 km, Change every 10,000 km or 12 months

Frequently check and add if needed. Shorten the change interval under severe conditions.

ASSY
Severe condition:
1. When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.
2. When most trips are less than 6 km (Operating when outside temperatures remain below freezing and when

HOUSING
most trips are less than 16 km)
3. When operating in dusty, sandy and salty areas
4. In hilly or moutainous terrain

EXHAUST I N T A K E
5. When doing frequent trailer towing

NOTICE
• Water separation from the fuel filter should be performed when changing the engine oil.

Engine Oil Changing Procedures

LUB
1. Park the vehicle on the level ground and warm up the
engine until it reaches normal operating temperature.
2. Stop the engine and wait around 5 minutes. Remove the

COOLING
oil filler cap, oil filter and oil drain plug to drain the oil.

NOTICE
• After driving, the engine oil temperature may be high

FUEL
enough to burn you. Wait until the oil is cooled down.

3. Install new oil filter and tighten the drain plug with

CONTROL
specified tighten torque.

Oil drain plug 25 ± 2.5 Nm

SENSOR
NOTICE
• Over-tightening may cause oil leaks.
• Replace the drain plug washer with new one.

4. Fill the engine oil through the oil filler opening.

NOTICE
• The oil should not go above the upper mark on the
dipstick. This would lead, for example, to increased
oil consumption, fouling of the spark plugs and ex-
cessive formation of carbon residue.

5. Close the oil filler cap and start the engine.

6. Stop the engine again and check the oil level. Add the
engine oil if needed and check for the oil leaks.

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
10 05

Engine oil filter change

1. For changing procedures, refer to the “Lubrication System” section in this manual.
1) Lubricate the engine oil gasket with engine oil before installation.
2) Tighten it with the specified tightening torque.

Oil filter 25 ± 2.5 Nm

Oil Filter and Cooler

- Removal and Installation
Preceding Works:
1. Draining of engine oil
2. Removal of EGR vacuum modulator bracket

1. Remove the oil cooler hoses (supply and return lines).

2. Disconnect the ground cable from the oil pressure

switch.

LUBRICATION SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 05 11

3. Remove the oil cooler and filter mounting bolt.

GENERAL
Installation Notice

Tightening torque 23 ± 2.3 Nm

ASSY
• Pay attention to the length of bolts.

HOUSING
EXHAUST I N T A K E
4. Remove the oil cooler and filter assembly from the
cylinder block.

NOTICE
• The oil cooler and filter assembly cannot be re-
placed separately.

LUB
COOLING
5. Install in the reverse order of removal.

FUEL
CONTROL
SENSOR

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
12 05

Oil Dipstick Guide Tube

- Removal and Installation
1. Pull out the engine oil dipstick.
2. Remove the EGR valve pipe (No.3).

Installation Notice
Tightening torque 35 ± 3.5 Nm

• Replace the pipe with new one.

3. Unscrew the bolt and remove the oil dipstick guide

tube.

Installation Notice
Tightening torque 10 Nm

• Replace the O-ring with new one.

4. Install in the reverse order of removal.

NOTICE
• After installation, check for oil leaks.

LUBRICATION SYSTEM CHANGED BY

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AFFECTED VIN
 05 13

OIL SPRAY NOZZLE

GENERAL
ASSY
a

HOUSING
1

EXHAUST I N T A K E
2

LUB
COOLING
1. Fitting sleeve 3. Combination bolt .............................................. 10 Nm
2. Oil spray nozzle a. Oil duct

FUEL
Disassembly

CONTROL
1. Remove the oil pan or crankshaft.
2. Unscrew the bolts and remove the nozzle.

SENSOR

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
14 05

OIL PAN ASSEMBLY

1. Oil pump 14. Washer

2. Oil pump cover 15. Bolt
3. Bolt 16. Oil pump roller chain
4. Drain plug washer 17. Oil pump chain lock link
5. Drain plug ....... 25 ± 2.5 Nm (replace the washer) 18. Oil pump chain tensioner
6. Spring pin 19. Oil pump chain spring
7. Oil pump drive shaft 20. Bush
8. Oil pump driven shaft 21. Oil pump sprocket
9. Oil pump relief valve piston 22. Bolt
10. Spring 23. Cylindrical pin
11. Oil pump relief valve pin 24. Oil pump sprocket assy
12. Oil pump relief valve plug 25. Oil pump screen assy
13. Bolt ............................................................. 10 Nm 26. Basket

LUBRICATION SYSTEM CHANGED BY

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AFFECTED VIN
 05 15

REMOVAL AND INSTALLATION OF OIL PAN AND OIL PUMP

GENERAL
Preceding Work:
1. Remove the negative battery cable.

ASSY
2. Drain the engine oil from the drain plug of the oil pan. (Store the drained engine oil in the specified container.)
3. Remove the front axle assembly. (For details, refer to “Chassis” section.)

HOUSING
Oil Pan Assembly
1. Unscrew the mounting bolt from the oil pan and separate the oil pan using a rubber hammer.

EXHAUST I N T A K E
10 mm mounting bolt
Tightening torque (10 ± 1 Nm)

LUB
COOLING
FUEL
Mounting location (RH)

Mounting Location (RH) CONTROL

SENSOR
M8 bolt M8 mounting bolt
Tightening torque (25 ± 2.5 Nm)

M6 mounting bolt M12 mounting bolt

Tightening torque Tightening torque
10 ± 1.0 Nm 55 ± 10 Nm

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
16 05

2. Remove the oil pan by lowering it to the front side (front bumper side).

NOTICE
• Be careful of the residual oil in the oil pan.

Oil Pan Assembly

Oil pan baffle plate

(integrated type)

When Installing

1. Wash out the oil pan to remove any foreign material.

2. Apply the specified sealant to the oil pan evenly (DB 2210: 661 989 56 A0).
3. Tighten the mounting bolt on the oil pan to the specified torque.

LUBRICATION SYSTEM CHANGED BY

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AFFECTED VIN
 05 17

GENERAL
Oil Pump and Oil Strainer
Preceding Work: Remove the oil pan assembly.

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
1. Unscrew three mounting hexagon bolts to remove the oil pump assembly.

FUEL
Hexagon Mounting Bolt (6 mm) Removal

CONTROL
SENSOR
Tightening
torque
25 ± 2.5 Nm

NOTICE
• Add the engine oil through the top of the oil pump when reinstalling the oil pump and the oil strainer.

CHANGED BY LUBRICATION SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
18 05

Oil Pump Components

Plunger

Oil pump

Compression
spring

Guide pin

Screw plug: 50 Nm Oil strainer

Mounting Bolt of Oil Pan and Tightening Torque

M6 x 85 bolt (3 EA)
10 ± 1.0 Nm

17 mm (TM side)
mounting bolt
55 ± 10 Nm

M6 x 20 bolt (20 EA) M6 x 35 bolt (3 EA) M8 x 40 bolt (4 EA)

10 ± 1.0 Nm 10 ± 1.0 Nm 25 ± 2.5 Nm

LUBRICATION SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 05 19

TROUBLE DIAGNOSIS

GENERAL
Symptom Cause Action

ASSY
• Loosened oil drain plug • Retighten
• Loosened oil pan bolts • Retighten
• Poor sealing at oil seal • Replace

HOUSING
• Loosened oil filter • Retighten
• Loosened oil pressure switch • Retighten

EXHAUST I N T A K E
• Poor sealing at camshaft front oil seal • Replace
• Poor sealing at crankshaft front oil seal • Replace
• Poor sealing at crankshaft rear oil seal • Replace
Excessive oil • Replace
• Poor sealing at cylinder head cover gasket
consumption
• Damaged cylinder head cover gasket • Replace
• Oil intrusion into combustion chamber • Clean
• Stuck piston ring • Remove carbon or replace ring

LUB
• Worn piston or cylinder • Boring or replace
• Worn piston ring or ring groove • Replace piston and piston ring

COOLING
• Improper position of ring cut-outs • Adjust
• Worn or damaged valve mechanism • Replace
• Oil leaks • Repair

FUEL
• Defective turbo charger • Check
Defective lubrication system
• Improper viscosity • Replace with specified oil

CONTROL
• Loosened oil pressure switch • Retighten
Low engine oil • Low engine oil level • Add
pressure
• Poor oil pump • Replace

SENSOR
• Worn or damaged oil pump relief valve • Replace
• Clogged oil filter or oil strainer • Replace or clean
• Oil leaks • Repair

CHANGED BY LUBRICATION SYSTEM

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AFFECTED VIN
20 05

MEMO
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LUBRICATION SYSTEM CHANGED BY

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AFFECTED VIN
COOLING SYSTEM
06

TABLE OF CONTENTS
COOLING SYSTEM ................................................. 2

ENGINE COOLING SYSTEM .................................. 3

Specifications ......................................................................... 12

INSPECTION AND REPAIR .................................. 13

Inspection ................................................................................ 13

REMOVAL AND INSTALLATION .......................... 15

PREHEATING SYSTEM ........................................ 34

Overview .................................................................................. 35
Preheating relay ...................................................................... 35
Preheating system diagram ................................................... 36
Preglow plug ........................................................................... 40
2 06

COOLING SYSTEM

Coolant Reservoir FFH Water Pump

Cooling Fan and Fan Coolant Temperature

Radiator Assembly
Clutch Sensor

COOLING SYSTEM CHANGED BY

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 06 3

ENGINE COOLING SYSTEM

GENERAL
ASSY
Coolant
reservoir
Engine

HOUSING
Cylinder head
Thermostat

EXHAUST I N T A K E
Heater
Radiator

Water pump Cylinder block

Oil cooler

LUB
(Heater line)

COOLING
<PTC Engine Coolant Flows>

Coolant
reservoir

FUEL
Engine

CONTROL
Cylinder head
Thermostat

Heater
Radiator

SENSOR
Water pump Cylinder block

Oil cooler

<FFH Engine Coolant Flows>

• Cylinder block side

Block #5 → Oil cooler → Heater → Heater water pump inlet pipe → Water pump
• Cylinder head side
Cylinder head → Coolant outlet port (intake #1) → Radiator → Water pump

CHANGED BY COOLING SYSTEM

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Function Description

Cylinder
head

Intake
manifold

Coolant
outlet port

1. Cylinder head coolant outlet port is integrated into intake manifold. (in front of cylinder #1)
: Improved shape and gasket material to prevent coolant from leaking

From cylinder head From reservoir

4
5
6

From heater

1 2 3

2. In OM 600 engine, coolant inflows through the heater line rear section (cylinder #4 and #5) of cylinder head.
However, in D27DT engine, coolant inflows from cylinder block through oil cooler (refer to coolant flows layout in
previous page).
: It prevents cooling efficiency from decreasing due to coolant separation between cylinder #4 and #5.

3. In OM 600 engine, the cooling fan is installed with water pump, however, in case of D27DT engine, it is connected
to water pump with an additional pulley.

COOLING SYSTEM CHANGED BY

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 06 5

Radiator

GENERAL
This vehicle has a lightweight tube-and-fin aluminum
radiator. Be careful not to damage the radiator core
when servicing.

ASSY
HOUSING
EXHAUST I N T A K E
Water pump
The belt-driven centrifugal water pump consists of an
impeller, a drive shaft, and a belt pulley. The impeller is
supported by a completely sealed bearing.
The water pump is serviced as an assembly and,
therefore, cannot be disassembled.

LUB
COOLING
Coolant reservoir

FUEL
NOTICE

CONTROL
• Scalding hot coolant and steam could be blown out
under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
engine and radiator are hot.

SENSOR
The coolant reservoir is a transparent plastic reservoir,
similar to the windshield washer reservoir. The coolant
reservoir is connected to the radiator by a hose and to
the engine cooling system by another hose. As the ve-
hicle is driven, the engine coolant heats and expands.
The portion of the engine coolant displaced by this ex-
pansion flows from the radiator and the engine into the
coolant reservoir. The air trapped in the radiator and
the engine is degassed into the coolant reservoir.
When the engine stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn
back into the radiator and the engine. This keeps the
radiator filled with the coolant to the desired level at all
times and increases the cooling efficiency. Maintain the
coolant level between the MIN and MAX marks on the
coolant reservoir when the system is cold.

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
6 06

Thermostat
A wax pellet-type thermostat controls the flow of the en-
gine coolant through the engine cooling system. The ther-
mostat is mounted in the water pump housing. The ther-
mostat stops the flow of the engine coolant from the en-
gine to the radiator to provide faster warm-up, and to regu-
late the coolant temperature. The thermostat remains
closed while the engine coolant is cold, preventing circu-
lation of the engine coolant through the radiator. At this
point, the engine coolant is allowed to circulate only
throughout the heater core to warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator where the
heat is dissipated. This opening and closing of the ther-
mostat permits enough engine coolant to enter the radia-
tor to keep the engine within proper engine temperature
operating limits. The wax pellet in the thermostat is her-
metically sealed in a metal case. The wax element of the
thermostat expands when it is heated and contracts when
it is cooled. As the vehicle is driven and the engine warms,
the engine coolant temperature increases. When the en-
gine coolant reaches a specified temperature, the wax
pellet element in the thermostat expands and exerts pres-
sure against the metal case, forcing the valve open. This
allows the engine coolant to flow through the engine cool-
ing system and cool the engine. As the wax pellet cools,
the contraction allows a spring to close the valve.
The thermostat begins to open at 85°C and is fully open
at 100°C. The thermostat closes at 85°C.

Operating
Thermostat Opening Value (mm)
Temperature (°C)
Begins to open 85°C 0.1 mm
Fully open 100°C 8 mm

COOLING SYSTEM CHANGED BY

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 06 7

When closed (up to 85°C)

GENERAL
X. from cylinder head
Y. to crankcase
Z. from radiator

ASSY
HOUSING
EXHAUST I N T A K E
When partially opened (85°C ~ 100°C)

LUB
COOLING
When fully opened (above 100°C)

FUEL
If the cooling system is fully filled with, the coolant is
automatically bled through ball valve (arrow) in

CONTROL
thermostat.

SENSOR

CHANGED BY COOLING SYSTEM

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8 06

Viscous fan clutch

The cooling speed increases approx. 1,000 rpm with wind
noise when the engine speed is 4,000 to 4,500 rpm and
the coolant temperature is 90 to 95°C.

NOTICE
• Keep hands, tools, and clothing away from the en-
gine cooling fans to help prevent personal injury.
This fan is electric and can turn on even when the
engine is not running.

NOTICE
• If a fan blade is bent or damaged in any way, no
attempt should be made to repair or reuse the dam-
aged part. A bent or damaged fan assembly should
always be replaced with a new one to prevent pos-
sible injury.

1. Clutch housing 9. Pin

2. Drive disc 10. Bi-metal
3. Flange 11. Bracket cover
4. Seal ring 12. Separator disc
5. Needle bearing 13. Supply port
6. Cooling fan 14. Lever valve
7. Oil scraper 15. Oil chamber
8. Spring 16. Operating chamber

The cooling fans are mounted behind the radiator in

the engine compartment. The electric cooling fans in-
crease the flow of air across the radiator fins and across
the condenser on air conditioner. The fan is 320 mm in
diameter with five blades to aid the airflow through the
radiator and the condenser. An electric motor attached
to the radiator support drives the fan.
1. A/C Off or Non-AC Model
1) The cooling fan operates at low speed when the
coolant temperature reaches 95°C and at high
speed when the coolant temperature reaches
100°C.
2) The cooling fan is turned from high speed to low
speed at 97°C and turns off at 90°C.

2. A/C On
1) The ECU will turn the cooling fan on at high speed
when the A/C system is on.

COOLING SYSTEM CHANGED BY

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 06 9

Engine coolant temperature sensor

GENERAL
The Engine Coolant Temperature (ECT) sensor uses a
temperature to control the signal voltage to the Engine
Control Unit (ECU).

ASSY
HOUSING
EXHAUST I N T A K E
Coolant Level Check

NOTICE
• Scalding hot coolant and steam could be blown out under pressure, which could cause serious injury. Never
remove the coolant reservoir cap when the engine and radiator are hot.

LUB
• Take precautions to prevent antifreeze coming in contact with the skin, eyes or vehicle body. If contact
happens, rinse affected areas immediately with plenty of water.

COOLING
1. Place the vehicle on a level ground and check the coolant level through the coolant reservoir.
2. Add if needed. Change the coolant if necessary.

FUEL
CONTROL
SENSOR

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
10 06

Coolant Temperature Sensor

Temp.

Resistance
<Coolant Temperature Sensor> <Output Characteristics of Coolant Temperature Sensor>

Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects
lowering signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if
engine temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete
combustion. So the sensor detects coolant temperature and changes coolant temperature changes into voltage
then sends to ECU to increase the fuel volume during cold start for better starting. And detects engine overheat-
ing for fuel volume reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
1. When engine is cold, controls fuel volume to correct idle speed
2. When engine is overheated, controls electrical fan and A/C compressor to protect the engine
3. Sends information for emission control

Temperature NTC 1 Resistance ( Ω ) NTC 2 Resistance ( Ω )

20 2,550 6,062
50 826 1,800
80 321 638
120 123 200

Signal

Auto amp

Ground

<Coolant Temperature Sensor Circuit>

COOLING SYSTEM CHANGED BY

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AFFECTED VIN
 06 11

Trouble Diagnosis

GENERAL
Symptom Cause Action
Low coolant • Leaks in radiator • Replace radiator
level

ASSY
• Leaks in coolant reservoir • Replace coolant reservoir
• Leaks in heater core • Replace heater
• Leaks in hose connection • Reconnect hose or replace clamp

HOUSING
• Damaged coolant hose • Replace hose
• Leaks in water pump gasket • Replace gasket
• Leaks in water pump internal seal • Replace water pump

EXHAUST I N T A K E
• Leaks in coolant inlet cap • Replace water inlet cap gasket
• Leaks in thermostat housing • Replace thermostat sealing
• Improper tightening torque of cylinder head • Retighten
• Damaged cylinder head gasket • Replace cylinder head gasket
Excessively • Coolant leaks (too low coolant level) • Add coolant
high coolant • Improper coolant mixture ratio • Check coolant concentration
temperature • Kinked coolant hose • Repair or replace hose

LUB
• Defective thermostat • Replace thermostat
• Defective water pump • Replace water pump
• Defective radiator • Replace radiator

COOLING
• Defective coolant reservoir and cap • Replace coolant reservoir or cap
• Cracks on cylinder head or cylinder block • Replace cylinder head or cylinder block
• Clogged coolant passages in cylinder head or cylinder block • Clean coolant passages

FUEL
• Clogged radiator core • Clean radiator core
• Improper operation of cooling fan • Replace cooling fan or repair related circuit
• Faulty temperature sensor or defective harness • Replace sensor or repair related circuit

CONTROL
Excessively • Stuck thermostat (with open) • Replace thermostat
low coolant • Improper operation of cooling fan • Replace cooling fan or repair related circuit
temperature
• Faulty temperature sensor or defective harness • Replace sensor or repair related circuit

SENSOR

CHANGED BY COOLING SYSTEM

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12 06

SPECIFICATIONS
Description Unit Specification
Cooling system Type - Water cooling forced circulation
Coolant Capacity 11.3
Thermostat Type - Wax pellet type
Initial opening temperature °C 85
Fully opening temperature °C 100
Fully closing temperature °C 83
Stroke mm min. 8
Cooling fan Blades 5
Diameter mm 320 (2)
Low speed ON temp °C 91
Low speed OFF temp °C 88
High speed ON temp °C 95
High speed OFF temp °C 92
High speed ON temp. (By A/C pressure) psi 270
Coolant reservoir Pressure valve opening pressure Kg/cm2 1.2 ~ 1.5
Vacuum valve opening pressure Kg/cm2 0.1
Water pump Type - Centrifugal
Impeller diameter mm 72.3
Impeller blades 10
Radiator Type - Down-flow
Core width mm 701
Core height mm 372
Core thickness mm 18
Minimum radiation capability Kcal/h 45,000
Coolant temperature Resistance (at 20°C) KΩ 3.33 ~ 3.78
sensor Resistance (at 80°C) KΩ 0.32 ~ 0.35
Anti-freeze agent Type − ALUTEC-P78
Mixture ratio (water and anti-freeze) − 50 : 50

COOLING SYSTEM CHANGED BY

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 06 13

INSPECTION AND REPAIR

GENERAL
INSPECTION

ASSY
Cooling System

HOUSING
1. Release the pressure from coolant reservoir by loos-
ening one notch of coolant reservoir cap, and then re-
move the cap.

EXHAUST I N T A K E
NOTICE
• Scalding hot coolant and steam could be blown out
under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90°C.

2. Add the coolant up to upper mark (arrow) on the

LUB
reservoir.
3. Install the tester to the coolant reservoir and apply the
pressure of 1.4 bar.

COOLING
4. Check the coolant hoses, pipes and connections for
leaks after the pointer of the tester drops. Replace or
retighten as required.

FUEL
CONTROL
Thermostat

SENSOR
Immerse the thermostat into the water. Heat the water Temperature gauge
and check the valve opening temperature.

Valve opening temperature DI Engine: 85 ± 2°C

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
14 06

Coolant Temperature Gauge Unit

1. Immerse the senor unit into the water. Heat the water
and check the resistance.

2. If the measured resistance is out of specified value,

replace the gauge unit.
3. Measure the resistance between terminal A and gauge
unit housing, and terminal B and gauge unit housing.
Terminal A Terminal B
Terminal A 0.4 Ω / 79°C
(for coolant temp.) 23.8 Ω / 115°C
Terminal B 24.8 Ω / -20°C
(for glow plug) 3.25 Ω / 20°C

Thermostat
1. Immerse the thermostat into the oil. Heat the oil until
it reaches the specified temperature and check if the
coolant temperature switch is turned “OFF”.
Coolant temperature at
113 ± 3°C
point A

Coolant temperature at
point B 116°C

NOTICE
• Use only engine oil for this inspection. Stir the oil
during heating it. Never heat the oil over required
temperature.

COOLING SYSTEM CHANGED BY

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 06 15

REMOVAL AND INSTALLATION

GENERAL
Coolant Hose (Inlet/Outlet)

ASSY
Preceding Work: Draining of coolant

1. Loosen the clamp and remove the coolant outlet hose

HOUSING
(engine to radiator).

EXHAUST I N T A K E
2. Disconnect the HFM sensor connector.
3. Remove the air intake duct from the air cleaner.

LUB
COOLING
FUEL
4. Loosen the clamp and remove the coolant inlet hose

CONTROL
(radiator to thermostat housing).

SENSOR

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
16 06

5. Lift up the vehicle and remove the skid plate.

6. Loosen the clamp and remove the lower inlet hose.

Shroud and Cooling Fan/Clutch

Preceding Work:
1. Draining of coolant
2. Removal of coolant inlet and outlet hose

1. Remove the air cleaner duct.

2. Release the clamps and remove the intake hose.

3. Unscrew the fan shroud mounting bolts.

COOLING SYSTEM CHANGED BY

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 06 17

5. Unscrew the center bolt and remove the cooling fan

GENERAL
clutch while holding the pulley with counter holder
(special tool).

Installation Notice

ASSY
Tightening torque 45 ± 4.5 Nm

HOUSING
EXHAUST I N T A K E
6. Remove the shroud.
7. Install in the reverse order of removal.

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
18 06

Water Pump - Assembly

Preceding Works: 1. Draining of coolant
2. Removal of V-belt
3. Removal of shroud
4. Removal of cooling fan

1. Thermostat housing 4. Belt pulley

2. Gasket ........................................................ Replace 5. Bolt ................................................................ 10 Nm
3. Bolt ................................................................ 10 Nm 6. Water pump bearing housing

COOLING SYSTEM CHANGED BY

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 06 19

1. Remove the V-belt while pressing down the auto

GENERAL
tensioner adjusting bolt.

ASSY
HOUSING
EXHAUST I N T A K E
2. Unscrew the bolts and remove the EGR pipe and
bracket.

Installation Notice
Tightening torque 23 ± 2.3 Nm

LUB
COOLING
3. Unscrew the bolts and remove the belt pulley while

FUEL
holding the belt pulley with a special tool.

Installation Notice

CONTROL
Tightening torque 10 Nm

SENSOR

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
20 06

NOTICE
• Replace the O-ring in oil dipstick with new one.
• Plug the oil dipstick hole with a cap not to get the
foreign materials into the engine.

5. Unscrew the bolts and remove the water pump

assembly.

Installation Notice
Tightening torque 10 Nm

NOTICE
• Remove the gasket residues from the sealing sur-
face and replace the gasket with new one.

6. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

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 06 21

GENERAL
Thermostat
Preceding Works: 1. Draining of coolant
2. Removal of V-belt

ASSY
3. Removal of cooling fan
4. Removal of intake duct (air cleaner to turbo charger)

HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
1. Gasket ...................................................... Replace 4. Thermostat

SENSOR
2. Water pump housing 5. Seal
3. Bolt .............................................................. 10 Nm 6. Coolant hose

CHANGED BY COOLING SYSTEM

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AFFECTED VIN
22 06

1. Unscrew the bolts and remove the thermostat housing.

Installation Notice
Tightening torque 10 ± 1.0 Nm

2. Remove the thermostat.

3. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

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 06 23

GENERAL
Water Pump Housing
Preceding Works:
1. Removal of water pump assembly

ASSY
2. Removal of thermostat assembly

1. Remove the heater hose.

HOUSING
EXHAUST I N T A K E
2. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque 46 ± 4.6 Nm

LUB
COOLING
3. Unscrew the bolts and remove the alternator bracket.

FUEL
Installation Notice
Tightening torque 25 ± 2.5 Nm

4. Unscrew the bolts and remove the water pump housing. CONTROL
SENSOR

Installation Notice
Tightening torque 10 ± 1.0 Nm

NOTICE
• Be careful not to damage the O-ring in coolant out-
let pipe (cylinder head side).
• Remove the gasket residues from the sealing sur-
face and replace the gasket with new one.

5. Install in the reverse order of removal.

CHANGED BY COOLING SYSTEM

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24 06

Radiator
Components of Radiator Module
Related Components (Assembly): Intercooler, Electric Fans, Condenser, Radiator
Preceding Works:
1. Disconnection of negative battery cable
2. Removal of front bumper assembly
3. Discharge of refrigerant
4. Draining of engine coolant

Removal Procedure

Intercooler Electric Fans

Radiator Condenser

COOLING SYSTEM CHANGED BY

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 06 25

GENERAL
Radiator and Intercooler
Preceding Works:
1. Collect the refrigerant from A/C system.

ASSY
2. Remove the lower cover.
3. Drain the engine coolant into the designated
container.

HOUSING
NOTICE
• Store the refrigerant and engine coolant in a safe

EXHAUST I N T A K E
place.

Removal and Installation

1. Remove the air cleaner duct.

LUB
COOLING
FUEL
2. Disconnect the intercooler hoses.

CONTROL
LH

Tightening torque: 6 ~ 7 Nm SENSOR

RH

Tightening torque: 6 ~ 7 Nm

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26 06

3. Remove the inlet, outlet and return hoses.

Inlet Hose Return Hose Outlet Hose

4. Remove A/C hose and condenser pipe.

High Pressure Pipe: Low Pressure Pipe:

compressor side receiver drier side

Tightening torque: 16 ~ 23 Nm

NOTICE
• Plug the openings of the pipes with sealing caps.

5. Unscrew the bolts and remove the radiator brackets.

COOLING SYSTEM CHANGED BY

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 06 27

6. Remove the transmission oil cooler pipes.

GENERAL
Installation Notice
Tightening torque 25 ~ 35 Nm

ASSY
HOUSING
EXHAUST I N T A K E
7. Pull out the fixing clips and remove the radiator.

LUB
COOLING
FUEL
8. Remove the outlet pipe from the intercooler.

Tightening torque 6 ~ 7 Nm

CONTROL
Release the clamp Remove two bolts
(10 mm)

SENSOR

Tightening torque: 6 ~ 7 Nm

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28 06

9. Unscrew the upper/lower mounting bolts (10 mm) and remove the intercooler from the radiator.

Intercooler Assembly

COOLING SYSTEM CHANGED BY

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 06 29

10. Remove the T/M oil cooler pipes from the radiator.

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
11. Unscrew five bolts (10 mm) and remove the condenser assembly from the radiator.

FUEL
Condenser

CONTROL
SENSOR

Radiator

CHANGED BY COOLING SYSTEM

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30 06

Replacement of Fan Belt

Preceding Work: Disconnect the negative battery cable.

1. Turn the fan belt adjusting bolt (19 mm) counterclockwise.

COOLING SYSTEM CHANGED BY

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 06 31

2. Remove the fan belt.

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
Fan Belt Arrangement

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY COOLING SYSTEM

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32 06

Coolant Reservoir
1. Drain the coolant.
2. Remove the hoses.

3. Unscrew the bolts and remove the coolant reservoir.

Installation Notice
Tightening torque 7 Nm

4. Install in the reverse order of removal.

COOLING SYSTEM CHANGED BY

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 06 33

GENERAL
Draining and Adding of Coolant
1. Release the pressure from coolant reservoir by loos-
ening one notch of coolant reservoir cap, and then re-

ASSY
move the cap.

NOTICE

HOUSING
• Scalding hot coolant and steam could be blown out
under pressure, which could cause serious injury.
Never remove the coolant reservoir cap when the
before the temperature goes down below 90°C.

EXHAUST I N T A K E
2. Loosen the drain plug in bottom of radiator and drain
the coolant.

NOTICE
• Collect the drained coolant with a proper container.

LUB
COOLING
3. Remove the drain plug and seal in the cylinder block

FUEL
and drain the coolant.
4. Replace the seal with new one and install the drain
plug.

CONTROL
Installation Notice
Tightening torque 30 Nm

5. Install the drain plug in bottom of radiator. SENSOR

6. Add the coolant through the coolant reservoir.

NOTICE
• Keep the coolant mixture ratio of 50:50 (water : anti-
freezer).
• Add the coolant until the water flows out through
the overflow hose.

7. Warm up the engine until the thermostat begins to

open and check if the coolant level is at “FULL” mark
on the reservoir. Add if necessary.
CHANGED BY COOLING SYSTEM
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34 06

PREHEATING SYSTEM

ECU Glow Indicator (Meter Cluster)

Glow plug

Preheat relay

Battery

No G5 for IG1 power supply

4 cylinders terminal Glow plug control
Tightening torque (Without D20DT) signal (ECU113)
when installing
15 ± 3 Nm
Ground
terminal

Battery main
wire
Preheat completion transmit
Glow plug terminal K-line
terminal : No use for vehicle
(#1 ~ #4) (ECU 34) without remote engine start

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OVERVIEW

GENERAL
Glow plug is installed on the cylinder head (combustion chamber) in the D20DT preheating control unit system. Cold
starting performance has improved and exhaust gas during cold starting has reduced.
ECU receives coolant temperature and engine speed to control; after monitoring the engine preheating/post heating

ASSY
and glow plug diagnosis function, the fault contents will be delivered to ECU.

1. Engine preheating/post heating functions

HOUSING
2. Preheating relay activation by ECU controls
1) Senses engine temperature and controls the preheating/after heating time
2) Glow indicator

EXHAUST I N T A K E
3. K-LINE for information exchanges between preheating unit and ECU
1) Transmits preheating unit self-diagnosis results to ECU
2) Transmits glow plug diagnosis results and operating status to ECU

PREHEATING RELAY

LUB
Structure

COOLING
FUEL
K-LINE #1 IG1
(ECU 34) Power terminal

CONTROL
Glow plug

SENSOR
control signal
(ECU 113)

Ground
terminal

B+main wire
(12V)
Glow plug
terminal

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PREHEATING SYSTEM DIAGRAM

Coolant
temperature
sensor 113

Specifications
Description Specification
Rated voltage DC 12 V
Operating voltage range DC 8 ~ 15 V
Operating range - 40 ~ + 100°C
Relay operating voltage Over 6.5 V
Relay releasing voltage Over 1.5 V
Relay coil resistance 11.3 Ω
Voltage drop Below 150 mV at each glow plug (at 16A of current)
Parasitic current MAX 1 mA

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Function

GENERAL
Preheating system controls and checks following functions and operating conditions.
Pre-Heating
1. The power will be supplied to the glow plugs by ECU controls when the power is supplied to the IG terminal from the

ASSY
battery and there are normal communications with ECU within 2 seconds. The surface of glow plug will be heated
up to 850°C very quickly to aid combustion by vaporizing air-fuel mixture during compression stroke.
2. Preheating time is controlled by ECU.

HOUSING
Post-heating
1. When the engine is started, post-heating starts by ECU controls. The idle rpm will be increased to reduce toxic
smoke, pollutants and noises.

EXHAUST I N T A K E
2. Post-heating time is controlled by ECU.
Checking glow plugs
1. Check each glow plug for short in circuit
2. Check each glow plug for open in circuit due to overvoltage
3. Check glow plug for short to ground
Forceful relay shut-down

LUB
1. When glow plug is shorted to ground
K-Line communication

COOLING
1. ECU sends the results to preheating time control relay through K-Line to start communication.
2. Preheating time control relay sends messages including self-diagnosis data for glow plugs to ECU.
3. Glow plug makes communication only as response to demand.
4. When power is supplied, ECU starts self-diagnosis within 2 seconds.

FUEL
5. Under the following conditions, communication error occurs.
1) When there is no response from glow plug module within 2 seconds

CONTROL
2) When an error is detected in checksum
3) Less byte is received

DTC

SENSOR
DTC Defective Detailed description
P1678 Glow plug open Preheat control driver open
P1679 Glow plug short Preheat control driver short
P1680 Glow plug - short to ground Preheat control driver is short to ground
P1676 Glow plug communication fault Communication fault between ECU and preheat controller
P1677 Defective glow plug controller Communication fault between ECU and preheat controller
P0671 Defective No. 3 glow plug No. 3 glow plug open
P0672 Defective No. 4 glow plug No. 4 glow plug open
P0673 Defective No. 5 glow plug No. 5 glow plug open (N/A for D20DT engine)
P0674 Defective No. 1 glow plug No. 1 glow plug open
P0675 Defective No. 2 glow plug No. 2 glow plug open

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Operating time

Coolant Temp. -35 °C -25 °C -20 °C -10 °C 0 °C 10 °C 20 °C

Pre- Operating Time 31 sec 22 sec 19 sec 17 sec 14 sec 0 sec 0 sec
heating Operating • IG: “ON” Release • After operating time elapsed
Conditions • B+ : below 15.2V Conditions • IG: “OFF” • When engine cranking

Coolant Temp. -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 35 °C

Operating Time 115 sec 80 sec 30 sec 19 sec 11 sec 11 sec 0 sec
Post-
heating • After engine starting • After operating time elapsed
Operating Release
• Torque : 190/170 Nm
Conditions Conditions
• Speed: 2100/2050 rpm
Coolant Temp. -30 °C -25 °C -20 °C -10 °C 0 °C 10 °C 20 °C
Glow Operating Time 18 sec 16 sec 10 sec 5 sec 2 sec 0 sec 0 sec
Indicator Operating Release
• IG: “ON” • When engine cranking
Conditions Conditions

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GENERAL
Removal and Installation
1. Turn the ignition switch to “OFF” position and discon-
nect the negative battery cable.

ASSY
2. Set aside the harnesses on the cylinder head.

HOUSING
EXHAUST I N T A K E
3. Disconnect the glow plug connectors and loosen the
glow plugs.

Installation Notice
Tightening torque

LUB
COOLING
4. Remove the glow plugs from the cylinder head with a

FUEL
special tool. Plug the openings of the glow plugs with
sealing caps.

CONTROL
SENSOR

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PREGLOW PLUG
Two versions of preglow plugs are used in this vehicle.
Always use only the designated version with correct color mark on insulator surface.

Specifications
BERU version NGK version
Color mark on insulator surface: Green Color mark on insulator surface: Yellow
Tip diameter: φ 4 Tip diameter: φ 3.5
Resistance: 680 ± 110 mΩ at 20 ± 2ºC Resistance: 1400 ± 300 mΩ at 20 ± 2ºC

Green Yellow

The color mark on insulator surface may be invisible due to the carbon contamination. To check the color easily,
disconnect the harness connector and clean the preglow plug mounting area with carbon cleaner.
Wait for a while and blow out the area with a compressed air.

Clean and Blow Out Check the Color Mark

Air gun
Check the color mark

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Preparations for Replacing Preglow Plug

GENERAL
Torque wrench, Air gun (small), Carbon cleaner (Product name: IPO CHOKE & CARBURATOR CLEANER, Model
name: PRO NO 5007, Manufacturer: Sunbo), Engine oil, Preglow plug wrench (special service tool), Long nose
pliers

ASSY
Removal and Installation of Preglow Plug
Preceding Work: Disconnect the negative battery cable.

HOUSING
1. Disconnect the wiring harness with long nose pliers and clean the preglow mounting area with the compressed
air (using air gun).

EXHAUST I N T A K E
Air gun

LUB
COOLING
2. Spray the carbon cleaner into the gap between preglow plug and cylinder head and wait for 10 minutes. Remove
the dirt and foreign materials completely with the compressed air (using air gun)..

FUEL
CONTROL
SENSOR

NOTICE
• At this moment, check the color mark on insulator surface and bring the same version of preglow plug for
replacement. (BERU: Green, NGK: Yellow)

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3. To avoid damage, apply the engine oil into the gap between preglow plug and cylinder head and wait for 5
minutes.

4. Remove the preglow plug with torque wrench. (tightening torque: 15 ± 3 Nm)

NOTICE
• To prevent the preglow plug from breaking, carefully turn the wrench with the torque below 20 Nm.
• Never use the air impact tool or other tools.

5. Thoroughly remove the foreign materials from the preglow plug hole. If needed, use the carbon cleaner or air gun.

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Remarks

GENERAL
1. Required tools

ASSY
Carbon Cleaner Torque Wrench (max. 25 Nm)

HOUSING
EXHAUST I N T A K E
Preglow plug wrench - Special Service Tool (10 mm)
Part number: Y99220132B

LUB
COOLING
2. Preglow plug circuit check

FUEL
1) Check the preglow plug trouble code with SCAN-100.
2) SCAN-100 can display only one trouble code. Check whether each preglow plug circuit is open with multi-
tester.

CONTROL
Color mark on BERU: Green

SENSOR
insulator surface
NGK: Yellow

Tip diameter BERU: 4 mm

NGK: 3.5 mm

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 FUEL SYSTEM
07

TABLE OF CONTENTS
CAUTIONS FOR DI ENGINE ................................... 2

FUEL SYSTEM ........................................................ 5

Fuel injection system ................................................................. 5
Fuel transfer line ...................................................................... 11
Inlet Metering Valve (IMV) ........................................................ 13
High fuel pressure line .............................................................. 16
Injector ..................................................................................... 38
2 07

CAUTIONS FOR DI ENGINE

This chapter describes the cautions for DI engine equipped vehicle. This includes the water separation from engine,
warning lights, symptoms when engine malfunctioning, causes and actions.

DI Engine Water Separator Warning Light

Comparatively conventional diesel engines, DI engine When the water level inside water
controls the fuel injection and timing electrically, deliv- separator in fuel filter exceeds a cer-
ers high power and reduces less emission. tain level (approx. 39 cc), this warn-
ing light comes on and buzzer
sounds.
System Safety Mode Also, the driving force of the vehicle
When a severe failure has been occurred in a vehicle, decreases (torque reduction). If these
the system safety mode is activated to protect the conditions occur, immediately drain
system. It reduces the driving force, restricts the engine the water from fuel filter.
speed (rpm) and stops engine operation. Refer to “Diag- For the draining procedures, please
nosis” section in this manual. refer to “How to drain the water from
fuel filter” section.

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Priming Pump

GENERAL
The priming pump installed in fuel pump is the device to fill the fuel into the fuel filter. When the vehicle is under the
conditions as below, press the priming pump until it becomes rigid before starting the engine.

ASSY
Conditions for Using Priming Pump
1. After run out of fuel

HOUSING
2. After draining the water from fuel separator
3. After replacing the fuel filter

EXHAUST I N T A K E
Fuel Filter and Water Separator

LUB
COOLING
FUEL
CONTROL
1. Fuel filter 3. Priming pump
2. Water drain plug
(water separating operation: every 10,000 km)

SENSOR
NOTICE
• When replaced the fuel filter or drained the water from fuel filter, press the priming pump until it becomes
rigid before starting the engine.
• The water drain from fuel filter should be performed whenever changing the engine oil.

CHANGED BY FUEL SYSTEM

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Draining the Water From Fuel Filter

1. Place the water container under the fuel filter.

2. Turn the drain plug (2) to “A” direction to drain the

water.
3. Wait until a certain amount of fuel gets out from the
port, then turn the drain plug to “B” direction to
tighten it.

NOTICE
• Be careful not to be injured by surrounding equip-
ment during the working procedures.

4. Press the priming pump until it becomes rigid.

5. Start the engine and check the conditions.

WARNING
• If the priming pump is not properly operated, air
may get into the fuel line. It may cause starting
problem or fuel system problem. Make sure to per-
form the job in step 4.

FUEL SYSTEM CHANGED BY

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FUEL SYSTEM

GENERAL
FUEL INJECTION SYSTEM

ASSY
Electronic Control of Fuel System
Fuel Pressure Sensor

HOUSING
High pressure Common Rail
pump

EXHAUST I N T A K E
IMV valve
Low and high
pressure pump High
Fuel temperature
sensor
Pressure
Pipe

LUB
Water separator
Water detection
sensor Priming
pump

COOLING
Label
(C2I)
Fuel
Filter

FUEL
Injector

CONTROL
Sensors

SENSOR
HFM sensor
Cam position sensor
Crank position sensor
Fuel tank ECU
Knock sensor etc.

Components:
- High pressure fuel pump Supply line
- Fuel rail - Fuel pressure sensor
Return line
- Fuel injectors - Electroc control unit (ECU) - Various sensors and actuators ECU
communication line

According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors via data line and then performs effective engine air-fuel ratio controls based on those
signals. Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines
injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that is generated by
variable resistance changes in accelerator pedal sensor. Air flow (hot film) sensor detects intake air volume and sends the
signals to ECU. Especially, the engine ECU controls the air-fuel ratio by recognizing instant air volume changes from air flow
sensor to decrease the emissions (EGR valve control). Furthermore, ECU uses signals from coolant temperature sensor
and air temperature sensor, booster pressure sensor and atmospheric pressure sensor as compensation signal to respond
to injection starting, pilot injection set values, various operations and variables.
CHANGED BY FUEL SYSTEM
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6 07

Composition of Fuel System

Components in fuel system are designed to generate and distribute high pressure, and they are controlled electroni-
cally by engine ECU. Accordingly, fuel system is completely different from injection pump type fuel supply system
on the conventional Diesel engine. The fuel injection system in common rail engine is composed of transfer pressure
section that transfers fuel in low pressure, high pressure section that transfers fuel in high pressure and ECU control
section.

Common rail

High pressure pipe

Fuel pressure
sensor

Injector
D20DT: 4 EA
D27DT: 5 EA

Priming pump

Fuel pump Fuel filter

(High pressure pump, transfer pump)

<Fuel Line System>

Fuel route

Transfer
Fuel Tank Priming Pump Fuel Filter
Pump

Transfer Pressure Line

High Pressure Fuel Pressure

Injector Common Rail
Pump Regulation Valve

High Pressure Line

FUEL SYSTEM CHANGED BY

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Hydranlic Cycle in Fuel Line (Tramsfer and High Pressure Line)

GENERAL
ASSY
Transfer pressure Pressure limiter
regulation (High pressure)

HOUSING
EXHAUST I N T A K E
Transfer pump High pressure pump

LUB
Return
valve

COOLING
Inlet
valve

below 2 bar

below -0.3

FUEL
bar Venturi Common rail
over
1050
bar

CONTROL
* IMV valve
fully open

SENSOR
Injector
Priming pump
Fuel
filter

Except D20DT
High pressure supply line
Transfer pressure supply
Fuel tank line
Return line

CHANGED BY FUEL SYSTEM

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8 07

Components of Low Pressure Transfer Line

Low pressure stage is to supply sufficient fuel to high pressure section and components are as below.
1. Fuel tank (including strainer)
2. Hand priming pump
3. Fuel filter
4. Transfer pump
5. Other low pressure fuel hoses

Fuel tank
Fuel tank is made of anti-corrosion material and its allow-
able pressure is 2 times of operating pressure (more than
min. 0.3 bar). It has protective cap and safety valve to
prevent excessive pressure building. Also, to supply fuel
smoothly, it has structure to prevent fuel from leaking in
shocks, slopes and corners and.

Priming pump
If fuel runs out during driving or air gets into fuel line after
fuel filter replacement, it may cause poor engine starting
or damage to each component. Therefore, the hand prim-
ing pump is installed to bleed air from transfer line.
When the vehicle is under the conditions as below, press
the priming pump until it becomes rigid before starting
the engine.
1. After run out of fuel
2. After draining the water from fuel separator
3. After replacing the fuel filter
Press the priming pump until it becomes rigid before start-
ing the engine.

Fuel filter
It requires more purified fuel supply than conventional die-
sel engine. If there are foreign materials in the fuel, fuel
system including pump components, delivery valve and
injector nozzles may be damaged.
Fuel filter purifies fuel before it reaches to high pressure
pump to help proper operations in high pressure pump.
And more, it separates water from fuel to prevent water
from getting into FIE system (high pressure line).

FUEL SYSTEM CHANGED BY

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 07 9

Components of High Pressure Transfer Line

GENERAL
In the high pressure section, sufficient fuel pressure that injectors requires will be generated and stored. The com-
ponents are as below:
1. High pressure pump

ASSY
2. Rail pressure sensor
3. Pressure limit valve
4. Common rail

HOUSING
5. High pressure pipe
6. Injector
7. Fuel pressure regulating valve (IMV)

EXHAUST I N T A K E
High pressure pump
This is plunger pump that generates high pressure; and
driven by crankshaft with timing chain. The high pressure
pump increases system pressure of fuel to approx.
1,600 bar and this compressed fuel is transferred to high
pressure accumulator (common rail) in tube through high

LUB
pressure line.

COOLING
Common rail

FUEL
It stores fuel transferred from high pressure pump and
also stores actual high pressure of fuel. Even though the

CONTROL
injectors inject fuel from the rail, the fuel pressure in the
rail is maintained to a specific value. It is because the
effect of accumulator is increased by unique elasticity of
fuel. Fuel pressure is measured by rail pressure sensor.

SENSOR
And the fuel pressure regulating valve (IMV, Inlet Meter-
ing Valve) included in high pressure pump housing keeps
pressure to a desired level.

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High pressure pipe (fuel pipe)

Fuel line transfers high pressure fuel. Accordingly, it is
made of steel to endure intermittent high frequency pres-
sure changes that occur under maximum system pres-
sure and injection stops. Injection lines between rail and
injectors are all in the same length; it means the lengths
between the rail and each injector are the same and the
differences in length are compensated by each bending.

Injectors
The fuel injection device is composed of electrical sole-
noid valve, needle and nozzle and controlled by engine
ECU. The injector nozzle opens when solenoid valve is
activated to directly inject the fuel into combustion cham-
ber in engine. When injector nozzle is open, remaining
fuel after injection returns to fuel tank through return line.
Pressure limit valve, fuel returned by low pressure and
fuel used for high pressure pump lubrication also return
to fuel tank through return line.

Transfer pump
The transfer pump is included in the housing of the high
pressure pump. The transfer pump is the volumetric blade
type pump. To deliver the continuously required fuel
volume, the pump transfers fuel from the fuel tank to high
pressure pump.

Fuel filter replacement

1. Fuel filter change interval: every 30,000 km
2. Water separation interval: every 10,000 km (same with
engine oil change interval)
3. Never reuse the removed fuel filter

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 07 11

FUEL TRANSFER LINE

GENERAL
Transfer Pump
Description

ASSY
The transfer pump is the device to provide sufficient fuel to high fuel pressure line and is mechanical type feed pump
that is driven by timing chain linked to crankshaft. This mechanical type feed pump is subject to air inflow, therefore,

HOUSING
a hand priming pump is installed to bleed air from fuel transfer line.
The transfer pump is included in the housing of the HP pump. The transfer pump is the volumetric blade type pump
and consists of the following components:

EXHAUST I N T A K E
1. A rotor turned by the shaft of the HP pump. The connection is provided by splines.
2. An eccentric liner fixed to the housing of the HP pump by 6 Torx bolts. The liner is positioned by two off-set pins
in order to prevent any assembly errors.
3. Four blades set at 90°. Each blade is held against the liner by a coil spring.
4. The inlet and outlet orifice.

LUB
COOLING
FUEL
CONTROL
Transfer pump HP pump

<Sectional Diagram of Fuel Pump>

SENSOR

<Sectional Diagram of Transfer Pump>

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Principle of operation

Housing Rotor

Blade
Chamber

Consider the chamber between the rotor, the liner and two successive blades (refer to above figure).
1. When the chamber is in position 1, the volume of the chamber is minimal. The changes in volume according to
the angle of rotation of the rotor are small.
2. The rotor makes a quarter turn clockwise. The previous chamber is now in position 2.
The inlet orifice is uncovered. The volume contained in the chamber quickly rises. The pressure inside the
chamber drops sharply. Fuel is drawn into the chamber.
3. The rotor continues to rotate. It is now in position 3. The inlet and outlet orifices are now sealed off. The volume
area controlled by the rotor, the liner and the two blades is at the maximum. The changes in volume according to
the angle of rotation of the rotor are small.
4. The rotor continues to rotate. It is finally in position 4. The outlet orifice is uncovered. The volume area controlled
by the rotor, the liner and the blades decreases quickly. The pressure inside the chamber rises sharply. The fuel
is expelled under pressure. The depression caused by the transfer pump’s rotation is sufficient to draw in diesel
fuel through the filter. The transfer pump is driven by the shaft of the HP pump, transfer pressure thus rises with
engine speed. A regulating valve allows the transfer pressure to be maintained at a practically constant level
(about 6 bar) throughout the whole range of engine operations by returning some of the fuel to the pump inlet.

Fuel
pressure
(bar)

Fuel pump speed (rpm)

Characteristics of the transfer pump

Regulating pressure 6 bar

Volume controlled 5.6 cm3/revolution
Flow 90 /h at 300 rpm pump
650 /h at 2,500 rpm pump
Intake capacity 65 mbar at 100 rpm pump

FUEL SYSTEM CHANGED BY

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 07 13

INLET METERING VALVE (IMV)

GENERAL
Overview
The LP actuator, also called the inlet metering valve, is

ASSY
used to control the rail pressure by regulating the amount
of fuel which is sent to the pumping element of the HP
pump.

HOUSING
EXHAUST I N T A K E
This actuator has two purposes: IMV effect
1. Firstly, it allows the efficiency of the injection system
to be improved, since the HP pump only compresses without IMV
with IMV
the amount of fuel necessary to maintain in the rail

LUB
the level of pressure required by the system as a func-
tion of the engine’s operating conditions.

COOLING
FUEL
Torque (Nm)
Rail pressure = 80 bar

2. Secondary, it allows the temperature to be reduced in

CONTROL
Fuel temperature at
the fuel tank. When the excess fuel is discharged into without IMV
system backleak
the back leak circuit, the pressure reduction in the with IMV
fluid (from rail pressure down to atmospheric pressure)
Fuel Temp.(°C)

gives off a large amount of heat. This leads to a tem-

SENSOR
perature rise in the fuel entering the tank. In order to
prevent too high a temperature being reached, it is
necessary to limit the amount of heat generated by
the fuel pressure reduction, by reducing the back leak
flow. To reduce the back leak flow, it is sufficient to
adapt the flow of the HP pump to the engine’s require-
ments throughout its operating range.
Torque (Nm)

CHANGED BY FUEL SYSTEM

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Composition of IMV
The IMV is located on the hydraulic head of the pump. It is fed with fuel by the transfer pump via two radial holes. A
cylindrical filter is fitted over the feed orifices of the IMV. This makes it possible to protect not only the LP actuator,
but also all the components of the injection system located downstream of the IMV.
The IMV consists of the following components:
1. A piston held in the fully open position by a spring.
2. A piston filter located at inlet.
3. Two O-rings ensuring pressure tightness between the hydraulic head and the body of the IMV.
4. A body provided with two radial inlet holes and an axial outlet hole.
5. Coil

Transfer pump Solenoid

Fuel
Filter Spring

High pressure Piston

Outlet hole O-ring

Fuel
Transfer pump

FUEL SYSTEM CHANGED BY

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 07 15

Principle of Operation

GENERAL
The LP actuator is used to proportion the amount of fuel sent to the pumping element of the HP pump in such a way
that the pressure measured by the HP sensor is equal to the pressure demand sent out by the ECU. At each point
of operation, it is necessary to have:

ASSY
• Flow introduced into the HP pump = Injected flow + Injector backleak flow + injector control flow
The IMV is normally open when it is not being supplied with fuel. It cannot therefore be used as a safety device to
shut down the engine if required.

HOUSING
The IMV is controlled by current. The flow/current law is represented below.

EXHAUST I N T A K E
Flow / Current Law
Flow (I/hr)

LUB
Current (mA)

COOLING
Specifications
Piston stroke 1.4 mm

FUEL
Diameter of holes 3.4 mm
Coil resistance 5.4 Ω (at 25°C)
Power supply Battery voltage (It is prohibited to supply the IMV directly at the battery voltage

CONTROL
during the diagnostic test)
Max. current 1A
Weight 260 g

SENSOR
Operating temperature 40°C < T < 125°C
Fluid temperature 40°C < T < 90°C
Control logic Normally open without power (The flow decreases as the current rises).

• ECU determines the value of the current to be sent to the IMV according to:

• Engine speed
E
• Flow demand • Inlet Metering
C
• Rail pressure demand Valve (IMV)
U
• Measured rail pressure

CHANGED BY FUEL SYSTEM

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16 07

HIGH FUEL PRESSURE LINE

High Pressure Pump
Description
This pump generates high fuel pressure and is driven by timing chain (radial plunger principle). This pump pressur-
izes the fuel to approx. 1600 bar and sends this high pressurized fuel to high pressure accumulator (common rail) via
high pressure line.
It is possible to extend the pumping phase in order to considerably reduce drive torque, vibration and noise since the
pump no longer determines the injection period. The differences from conventional rotary pumps lies in the fact that
it is no longer the hydraulic head rotor which turns inside the cam, but the cam which turns around the hydraulic
head. Thus, any problems of dynamic pressure tightness are eliminated because the high pressure is generated in
the fixed part of the pump.

1. IMV (Inlet Metering Valve)

2. Hydraulic Head
3. Plunger
4. Drive shaft and cam ring
5. Housing
6. Roller and shoe
7. Transfer pump
8. Fuel temperature sensor
Fuel 9. Vent
discharge
10. High fuel pressure - OUT
11. Pressure regulator

Fuel supply

Specifications
1. Maximum operating pressure: 1600 ± 150 bar
2. Operating pressure limit: 2100 bar
3. Maximum sealing pressure: when using a plug instead of PRV, no leaks around pump outlet port (when
applying 2500 bar of constant pressure)
4. Fuel pressure at inlet (pressure regulating valve): 6 bar
5. Operating temperature: Continuously operating within temperature range of -30°C ~ 120°C in engine compartment
6. Inflowing fuel temperature: The maximum inflowing fuel temperature is 85°C (continuously able to operate)
7. Pump inlet pressure: Relative pressure Max. 048 bar (to end of filter’s lifetime)
8. Driving torque: 15 Nm / 1600 bar
9. Gear ratio (engine: pump): 0.625
10. Lubrication: - Inside lubrication (rear bearing): Fuel
- Outside lubrication (front bearing): Engine oil

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Principle of operation

GENERAL
1. During the filling phase, the rollers are kept in contact with the cam by means of coil springs mounted on either
side of each shoe. The transfer pressure is sufficient to open the inlet valve and to move the pumping plungers
apart. Thus, the dead volume between the two plungers fills with fuel.

ASSY
2. When the diametrically opposite rollers simultaneously encounter the leading edge of the cam, the plungers are
pushed towards each other.
3. As soon as the pressure becomes higher than the transfer pressure, the inlet valve closes. When the pressure

HOUSING
becomes higher than the pressure inside the rail, the delivery valve opens. Consequently, the fuel is pumped
under pressure into the rail.
4. During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping
element. The valve closes as soon as the pressure in the pumping element becomes higher than the transfer

EXHAUST I N T A K E
pressure.
5. During the input phase, the ball of the delivery valve is subject to the rail pressure on its outer face and to the
transfer pressure on its inner face. Thus the ball rests on its seat, ensuring the pressure tightness of the body of
the pumping element. When the pressure in the element becomes higher than the pressure in the rail, the ball is
unbalanced and it opens. Fuel is then pumped into the rail at high pressure.

LUB
Roller

COOLING
FUEL
CONTROL
Plunger

<Fuel Input> <Pressurize>

SENSOR
This high pressure pump generates the driving torque with low peak torque to maintain the stress to driving components.
This torque is smaller than that of conventional injection pump, thus, only a small load will be applied to pump. The
required power to drive pump is determined by set pressure for rail and pump speed (delivery flow). Note that the fuel
leakage or defective pressure control valve may affect the engine output.

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Inlet valve and delivery valve

During the input phase, transfer pressure pushes back the inlet valve. Fuel enters the body of the pumping element.
Under the effect of the transfer pressure, the two plungers are forced apart. When the rollers simultaneously encoun-
ter the leading edge of the cam, pressure suddenly rises in the body. Of the pumping element. The valve closes as
soon as the pressure in the pumping element becomes higher than the transfer pressure. During the input phase,
the ball of the delivery valve is subject to the rail pressure on its outer face and to the transfer pressure on its inner
face. Thus the ball rests on its seat, ensuring the pressure tightness of the body of the pumping element. When the
two diametrically opposite rollers encounter the leading edges of the cam, the plungers are forced together and
pressure quickly rises in the body of the pumping element. When the pressure in the element becomes higher than
the pressure in the rail, the ball is unbalanced and it opens. The spring calibration is negligible compared with the
pressure forces. Fuel is then pumped into the rail at high pressure.

<Inlet Valve> <Delivery Valve>

Lubrication and cooling of the HP pump

Lubrication and cooling of the pump are provided by the fuel circulation. The minimum flow required to ensure
adequate operation of the pump is 50 /h.

Phasing of the HP pump

Conventional fuel injection pumps ensure pressurizing and distribution of the fuel to the different injectors. It is
essential to set the pump in such a way that the injection occurs at the required place during the cycle. The HP
pump of the common rail system is no longer used for the fuel distribution, it is therefore not necessary to set the
pump in relation to the engine.
Nevertheless, the setting or phasing of the pump offers two advantages:
1. It allows the torque variations of the camshaft and the pump to be synchronized in order to reduce the stresses
on the timing belt.
2. It allows pressure control to be improved by synchronizing peak pressures produced by the pump with pressure-
drops caused by each injection.
This phasing allows pressure stability to be improved, which helps to reduce the difference in flow between the
cylinders.

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HP Pump Fuel Route

GENERAL
The fuel passed through the fuel filter is sent to the transfer pump via the HP inlet pump. this fuel passes through the
transfer pump by the transferring pressure and maintains the predefined value by the regulating valve in HP pump.
Also, this fuel gets into the IMV that controls only the fuel to the high pressure pump.

ASSY
The below figure describes the pump operations when acceleration and deceleration.

When need high fuel pressure (acceleration)

HOUSING
IMV open

EXHAUST I N T A K E
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Venturi

to common

COOLING
rail

Fuel supply

FUEL
to fuel tank
Backleak

CONTROL
SENSOR

Transfer pump High pressure pump

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When do not need high fuel pressure (deceleration)

IMV close

Venturi

to common
rail

Fuel supply
to fuel tank
Backleak

Transfer pump High pressure pump

The fuel is sent to the high pressure side (hydraulic head) and compressed by the plunger. And, goes into the
common rail through the high pressure pipe.
The IMV installed in the high pressure side (hydraulic head) of HP pump precisely controls the fuel amount and
delivers the rail pressure feedback same as required amount.
The IMV is controlled by ECU.

Performance curve of HP pump

The time required to obtain a sufficient pressure in the rail to enable the engine to start depends on the volume of the
system (definition of the rail, length of the pipes, etc.). The aim is to reach a pressure of 200 bars in 1.5 revolutions
(3rd compression).
• Maximum operating pressure: 1600 ± 150 bar
Rail pressure (bar)

Engine speed (rpm)

<Pressure Curve of HP Pump>

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Sectional View of HP Pump

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
<Transfer Pump>

FUEL
CONTROL
IMV valve

SENSOR

High pressure
pump

<IMV Valve and High Pressure Pump (Drive Shaft)>

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Inlet valve

Temperature
sensor

Shoe and roller Supply valve

<Inlet Valve, Outlet Valve, Shoe and Roller, Temperature Sensor>

<Hydraulic Head>

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Removal and Installation

GENERAL
Removal

Preceding Works:

ASSY
1. Disconnect the negative battery cable.
2. Apply the parking brake and place the chocks
under the tires. (transmission "N" position)

HOUSING
EXHAUST I N T A K E
1. Turn the auto tensioner counterclockwise and re-
move the fan belt.

NOTICE
• Slacken the pulley bolt.

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COOLING
2. Remove the engine belt pulleys.

FUEL
1) Cooling fan pulley
2) Coolant pump pulley

CONTROL
3) Idle pulley

3. Unscrew lower bolt (13 mm) and upper bolt (24 mm) SENSOR
and remove the auto tensioner.

NOTICE
• To prevent oil leaks, store the removed auto
tensioner in upright position.
• Pump the suto tensioner several times before in-
stalling it.

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6. Remove the high pressure pump housing.

Preceding Work: Remove the No.2 EGR pipe.

7. Align the OT mark by rotating the crankshaft.

1) Open the oil filler cap and check if the OT mark
on crankshaft is aligned to the notch on the
camshaft.

8. Unscrew the bolts and remove the vacuum modu-

lator bracket.
1) Disconnect the high pressure pump and vacuum
modulator connector.
2) Disconnect the fuel lines to high pressure pump.
3) Plug the openings of pipes and ports with pro-
tective caps to keep the cleanness of the fuel
system.
4) Remove the high pressure fuel pipe between
HP pump and common rail.

9. Rotate the crankshaft clockwise so that the HP

pump sprocket holes are aligned to the bolt holes.

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8. Hold the HP pump sprocket and slacken the

GENERAL
center bolt.

ASSY
HOUSING
EXHAUST I N T A K E
9. Slacken three HP pump mounting bolts until they
rest on the sprocket.

LUB
COOLING
FUEL
10. Loose the HP pump center nut by tapping it with
a hammer.

CONTROL
NOTICE
• Tap the center bolt with a hammer after tightening.
• Make sure that the center bolt is securely tightened.

11. Remove the remaining bolts with the same manner SENSOR

and remove the high pressure pump.

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Installation

1. Replace the HP pump gasket with new one (cannot

be reused).

2. Tighten the HP pump bolts.

Tightening torque 25 Nm

3. Hold the HP pump sprocket and tighten the center

nut.

Tightening torque 65 Nm

NOTICE
• The center nut should be replaced once removed
(cannot be reused).
• Tighten the center nut with the specified tighten-
ing torque.

4. Install the vacuum modulator bracket.

NOTICE
• Replace the fuel lines to HP pump with new ones
(cannot be reused).
• Make sure that the connectors are installed to the
correct locations. (The wiring end with white tape

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5. Apply the sealant to the HP pump housing and

GENERAL
tighten the bolts.

NOTICE

ASSY
• Sealant (DB2210): 661 989 56 A0

HOUSING
EXHAUST I N T A K E
6. Install the auto tensioner and belt pulleys.

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COOLING
7. Rotate the crankshaft pulley two revolutions and en-

FUEL
sure that the OT mark on the crankshaft pulley and
the OT mark on the camshaft pulley are aligned.

CONTROL
NOTICE
• Open the oil filler cap and check if the OT mark on
crankshaft is aligned to the notch on the camshaft.

SENSOR

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Fuel Filter
Function
Foreign materials in fuel can damage the pump components, transfer valve and injectors. Therefore, the high
pressure direct injection engine must use fuel filter. Otherwise, the operation performance will drop dramatically.
And, diesel fuel may contain water due to condensation by temperature changes and this condensation water
can damage the system by corroding the injection system. Thus, the common rail engine should have function
that can drain water periodically.

from HP pump to fuel tank

to HP
pump
from fuel tank

Fuel filter
Water Sensor Fuel level in filter: 500 ± 25 cm3
Effective water storing rolame: 120cc Filtering effective
Warning light ON level: 39 cc • Particles larger than 3µm > 98 %
• Particles larger than 5µm > 99.8 %
• Particles larger than 15µm > 100 %

Drain plug

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Change Interval: 30,000 km

GENERAL
Water separation and storage function
1. Function: It separates the condensation water from diesel fuel to prevent the water from getting into FIE system,
and results in protection of FIE system. (manual drain)

ASSY
2. Water reserve capacity: 124 cc
3. Water warning light turning on level: 39 cc

HOUSING
4. Water drain interval: When changing engine oil or every 20,000 km

Water sensor

EXHAUST I N T A K E
It is integrated in the filter and sends signal to ECU when water level reaches at a specified value (over 75 cc) in
the filter to let the driver drain the water.

Fuel De-Waxing – Improving starting performance in cold weather

Due to characteristics of diesel fuel, some of fuel components solidify during cold winter under below a specific
temperature (-15°C). When those symptoms happen, engine may stall; however, some of the fuel (temperature

LUB
rises due to high compression) in the HP pump in D27DT engine return to the filter to warm up fuel when
temperature is below 50°C by improving cold start performance during cold winter.

COOLING
FUEL
CONTROL
SENSOR

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Removal and Installation

1. Disconnect the fuel supply and return hoses.

NOTICE
• Plug the openings of hoses and fuel filter with seal-
ing caps.
• Ensure that the hoses are connected to correct
positions.

2. Loosen the bracket bolts and disconnect the hose from

the drain plug.
3. Remove the fuel filter.
4. Install in the reverse order of removal.
5. Press the priming pump until it becomes rigid to de-
liver the fuel to the transfer line of HP pump.

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Priming Pump

GENERAL
If fuel runs out during driving or air gets into fuel line after
fuel filter replacement, it may cause poor engine starting
or damage to each component. Therefore, the hand prim-

ASSY
ing pump is installed to bleed air from transfer line.
to fuel
When the vehicle is under the conditions as below, press filter
the priming pump until it becomes rigid before starting

HOUSING
the engine.
Conditions for using Priming Pump
1. After run out of fuel from fuel
tank

EXHAUST I N T A K E
2. After draining the water from fuel separator
3. After replacing the fuel filter

NOTICE
• When the fuel filter is replaced, the fuel in the fuel tank should be transferred to the filter by using priming
pump. So never transfer the fuel in the fuel tank to the filter by driving HP pump with cranking the engine.

LUB
Relations Between Pressure and Temperature in Fuel Transfer Line

COOLING
Pump inlet pressure

FUEL
Pump

High pressure common rail

CONTROL
Fuel transfer
line

SENSOR
Injector
Ventury

Pump outlet Injector No.1 return Injector No.5 return

pressure pressure pressure

1. The fuel transfer line is the line between fuel tank and HP pump inlet port. The pressure on this line affects the
lifetime of fuel filter.
2. Temperature of fuel transfer line
1) Pump inlet temperature is less than 80°C.
2) Above figure shows the temperature changes in each section caused by temperature changes in pump inlet
section; the temperature of fuel pump inlet is up to 80°C.
And, diesel fuel has lubrication effects due to its viscosity. Thus, the fuel is also used for pump lubrication.
However, this lubrication performance drops as the temperature rises. Accordingly, when the fuel temperature
is over 50°C, 100% of fuel is returned to fuel tank to cool down the temperature and then increase the
lubrication effects of fuel and prevent heat damage on each section of high fuel pressure line.
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High Pressure Accumulator (Common Rail)

Description
The high pressure accumulator reserves the high pressure fuel. Simultaneously, the pressure changes due to
the delivery from HP pump and the fuel injection is diminished by rail volume. This high pressure accumulator is
commonly used in all cylinders. Even when a large amount of fuel leaks, the common rail maintains its internal
pressure. This ensures that the injection pressure can be maintained from when the injector opens.

Function
1. Relieve the pressure pulsation
2. Provide pressure information to ECU (fuel pressure sensor)

Specifications
1. Material: Forged Steel
2. Dimension: • Volume: 19.5 ± 1cc
• Length: Max. 345.11 mm
• Outer diameter: 27 mm

3. Fuel pressure sensor Integrated type

1) Sensor input voltage: 5 ± 0.1V
2) Sensor output signal voltage: • 4.055 ± 0.125 V ≅ 1600 ± 15 bar
• 0.5 ± 0.04 V ≅ 0 bar
4. Operating pressure range
1) Normal condition: 0 ~ 1800 bar
2) Exceptional condition: available within 1800 ~ 2100 bar
3) Bursting pressure: over 2500 bar

5. Ambient temperature:
1) available within -40°C ~ 125°C
2) Spontaneous max. temperature after engine stops: 140°C (acceptable against total 15 hours)

6. Fluid temperature: -40 ~ 100°C under normal operating conditions

7. Removal and installation: 10 times without any damage

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GENERAL
D20DT No. 1 No. 3 No. 4 No. 2
D27DT No. 1 No. 2 No. 3 No. 4 No. 5

ASSY
HP pipe

HOUSING
Injector
High fuel pressure

EXHAUST I N T A K E
pipe

HP pipe
Fuel pressure
sensor

LUB
COOLING
HP pump

<High Pressure Accumulator>

FUEL
CONTROL
High Fuel Pressure Pipe
1. Function: Resistant to pressure changes, tightness against surroundings, supplying fuel through pump, rail and
injector with high pressure

SENSOR
2. Material: Steel (Zn Plated)
3. Common: Cylinder 1, 2, 3, 4
4. Internal pressure
1) Internal operating pressure: 0 ~ 1600 bar during its lifetime
2) Spontaneous max. pressure when restoring: 2100 bar (max. total period: 20 hours)
3) Bursting pressure: over 2500 bar
5. To keep cleanness and tightness, the high pressure pipe assembly should be used only once.

NOTICE
• Make sure to replace the removed high fuel pressure pipes.
• Tighten the fasteners with the specified tightening torque.

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Removal and Installation

Preceding Work: Removal of engine cover

1. Disconnect the fuel pressure sensor connector.

NOTICE
• Replace the fuel pipes with new ones.
• Plug the openings of hole in the common rail with
sealing caps.

2. Unscrew the nuts and remove the fuel supply main

pipe from the fuel line.
Installation Notice
Tightening torque 40 ± 1.0 Nm

NOTICE
• Replace the fuel pipes with new ones.
• Plug the openings of hole in the common rail with
sealing caps.

3. Unscrew the high fuel pressure line nuts and remove

the fuel pipes.
Installation Notice
Tightening torque 40 ± 1.0 Nm

NOTICE
• Replace the fuel pipes with new ones.
• Plug the openings of hole in the common rail with
sealing caps.

4. Unscrew the bolts and remove the common rail

asssembly.

Installation Notice
Tightening torque 25 ± 2.5 Nm

NOTICE
• Replace the fuel pipes with new ones.
• Plug the openings of hole in the common rail with
sealing caps.

5. Install in the reverse order of removal.

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Fuel Pressure Sensor

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
Fuel pressure sensor on the center of common rail detects instant fuel pressure changes and then sends to ECU.
When received these signals, ECU uses them to control fuel volume and injection time.
The fuel in the rail reaches to sensor diaphragm via blind hole in the pressure sensor and the pressure signal
converts to electrical signal. The signal measured by sensor will be amplified to input to ECU.

FUEL
This piezo element type sensor changes pressure into electrical signal. Accordingly, when the shape of diaphragm
changes, electrical resistance in the layers on the diaphragm changes then can measure 0.5 ~ 5 V.
1. Sensor input voltage: 5 ± 0.1 V

CONTROL
2. Output signal voltage of sensor
1) 4.055 ± 0.125 V: 1600 ± 15 bar
2) 0.5 ± 0.04 V: 0 bar

SENSOR

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Sensing area Amplifier

Pres- Physical
Converts to Electrically
sure changes
electric signal amplyfying
signal

<Operation Principle of Fuel Pressure Sensor>

Upper area

Output
voltage

Lower area

Pressure (P)

<Sensor Voltage>

Piezo resistance

Ground

SIG

REF 5V
Pressure sensor

<Circuit Diagram of Fuel Pressuer Sensor>

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Fuel Temperature Sensor

GENERAL
Temperature

ASSY
HOUSING
EXHAUST I N T A K E
Resistance

<Fuel Temperature Sensor> <Output Characteristics of Fuel Temperature Sensor>

Fuel temperature sensor is a NTC resistor that sends fuel temperature to ECU.
In case of NTC resistor, the resistance lowers if engine temperature rises so the ECU detects lowering signal
voltages.
Fuel temperature sensor is installed on the fuel return line to correct pressure after measuring fuel temperature.

LUB
5V is supplied to the sensor and voltage drop by temperature is delivered to ECU to measure the fuel tempera-
ture through analog-digital converter (ADC).

COOLING
Signal

FUEL
Fuel Temp

CONTROL
Sensor

Ground

SENSOR
<Circuit Diagram of Fuel Temperature Sensor>

HFM Sensor
Refer to “Intake System”

Crankshaft Position Sensor

Refer to “Engine Assembly”

Knock Sensor
Refer to “Engine Assembly”

Camshaft Position Sensor

Refer to “Engine Assembly”
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INJECTOR
The C21 labels including injector characteristics are attached in each injector. These C21 values should be input to
ECU by using Scan-i when replacing the ECU or injectors.

Special cautions:
1. Plug the openings of hoses and pipes with the sealing caps.
2. Replace the copper washer in injector with new one.
3. Tighten the injector holder bolts with the specified tightening torque.
4. Be careful not to drop the injector.

Specifications
Length: · Injector body 181.35 mm
· Injector nozzle 22.155 mm
Nozzle basic: 5 Holes, 150° Cone
Angle, 890 mm3/min
Control: PWM type (solenoid injector)
Tightening: By clamping fork
Fuel return: Nipple
Edge filter

Leak off
nipple

C2I label

Nozzle holder body

Bobbin

C2I value Control valve

Cap nut Adaptor plate

Nozzle body

Washer
Nozzle needle

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GENERAL
The maximum injection pressures are approximately 1,600 bar. The forces to be overcome in order to lift the needle
of the injector are therefore very large. Because of this, it is impossible to directly control the injector by using an
electromagnetic actuator, unless very high currents are used, which would be incompatible with the reaction times

ASSY
required for the multiple injections. The injector is therefore indirectly controlled by means of a valve controlling the
pressurizing or discharging of the control chamber located above the needle:
1. When the needle is required to lift (at the start of injection): the valve is opened in order to discharge the control

HOUSING
chamber into the back leak circuit.
2. When the needle has to close (at the end of injection): the valve closes again so that pressure is re-established
in the control chamber.

EXHAUST I N T A K E
Valve Valve
In order to guarantee response time and minimum en-
ergy consumption:
1. The valve must be as light as possible. Vo l u m e Contact
under making seal
2. The valve stroke must be as short as possible.
high
3. The effort needed to move the valve must be minimal, pressure

LUB
Depressuriza-
which means that the valve must be in hydraulic equi- Valve tion grooves
librium in the closed position. Spill Vo l u m e
orifice under
Spring pressure ensures contact between the valve and

COOLING
vacuum
its seat. To lift the valve, it is therefore required to over-
come the force being applied by this spring.

Spacer

FUEL
Spacer
The spacer is situated underneath the valve support. It
integrates the control chamber and the three calibrated

CONTROL
orifice which allow operation of the injector. These ori- INO inlet SPO spill
irifice orifice
fices are:
1. The injector supply orifice (Nozzle Path Orifice: NPO)
2. The control chamber discharge orifice (Spill Orifice:

SENSOR
Control
SPO) NOP nozzle
chamber
path orifice
3. The control chamber filling orifice (Inlet Orifice: INO)

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Principle of Operation

FfFf= pressure
= * space
S
(Ff
(Ff==Prail
Pr* S)

Fo = pressure * space
Fo==Prail * S)
(Fo
(Fo = A)

Valve closed Valve opens Valve closes Valve closed

Needle Needle Needle open Needle
closed closed End of closed
No injection No injection injection No injection

Injector at rest
The valve is closed. The control chamber is subject to
the rail pressure.
The pressure force applied by the fuel onto the needle is:
Ff = S * Prail
The needle is closed and hence there is no fluid circu-
lation through the NPO orifice. While static, the nozzle
produces no pressure drop. The cone of the needle is
therefore subject to the rail pressure. The force ap-
plied by the fuel to the needle is:
Fo = A * Prail
Since Ff > Fo, the needle is held in the closed position.
There is no injection.

Solenoid valve control

When the solenoid valve is energized, the valve opens. * S: The area of the flat upper surface of the injector’s needle
* A: The area of the needle surface situated above the section
The fuel contained in the control chamber is expelled of contact between the needle and its seat
through the discharge orifice known as the Spill Orifice * Ff: The force applied by the fuel onto section “S”
(SPO). * Fo: The force applied by the fuel onto section “A”
As soon as Ff > Fo, the needle remains held against its
seat and there is no injection.

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GENERAL
Start of injection
As soon as Ff < Fo, or in other words:

ASSY
Pcontrol < Prail * A/S
The needle lifts and injection begins. As long as the valve is open, the injector’s needle remains lifted. When
injection begins, fuel circulation is established to feed the injector. The passage of the fuel through the inlet
orifice of the injector (similar to a nozzle) leads to a pressure drop which depends on the rail pressure.

HOUSING
When the rail pressure is at its highest (1600 bar), this pressure drop exceeds 100 bar. The pressure applied
to the cone of the needle (the injection pressure) is therefore lower than the rail pressure.

EXHAUST I N T A K E
End of injection
As soon as the solenoid valve is de-energized, the valve closes and the control chamber is filled. Since the
needle is open, the thrust section areas situated on either side of the needle is therefore to apply different
pressures to each of these faces. The pressure in the control chamber cannot exceed the rail pressure, so it is
therefore necessary to limit the pressure applied to the needle’s cone. This pressure limitation is achieved by
the NPO orifice which produces a pressure drop when fuel is passing through it.

LUB
Prail * S (Prail - P) * S
When static, this pressure drop is zero. When the pressure in the control chamber becomes higher than the
pressure applied to the needle’s cone, the injection stops.

COOLING
FUEL
CONTROL
SENSOR

CHANGED BY FUEL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
42 07

Fuel Pressure
Fuel pressure
1. Minimum operating pressure: start injection over 100 bar
2. Maximum operating pressure: 1,600 bar (max. operating pressure in normal conditions)
3. Operating pressure limit: 2,100 bar

Maximum fuel volume at each injector cycle

1. Pilot Injection 5 mm3
2. Main Injection 85 mm3 (within 200 ~ 1,600 bar)

Main injection

Pilot injection

Small injection
separation

3. Small injection separation: min. 200

Opening Delay Definition
(duration between the end of pilot injection and start
of main injection)

4. Opening Delay
10%
: Delayed time from applying operating voltage to start signal
amplitude Injection rate
of injection Injector drive pulse

5. Adjustment of feedback injection volume: C2I

10%
signal
amplitude

Time ( )

FUEL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 07 43

Injector Control

GENERAL
Current

ASSY
Peak pull
current = 22.0 A

Through pull

HOUSING
current = 7.5 A
Peak hold
current = 22.0
A
Through hold
current = 7.5 A

EXHAUST I N T A K E
Time
Pull-in period Hold period

LUB
The control current of the coil takes the following form:

COOLING
1. The low current allows the Joule effect losses in the ECU and injector to be reduced. The call current is higher
than the hold current because during the hold phase.
2. The air gap between the valve and the coil is reduced and the electromagnetic force to be applied to the valve can
thus be reduced. It is no longer necessary to overcome the valve inertia.

FUEL
NOTE
• Joule Effect: Heat capacity (H) = 0.24 I 2RT

CONTROL
SENSOR

CHANGED BY FUEL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
44 07

Fuel Injection
Other than conventional diesel engine, common diesel engine use two steps injection as follows:
1. Pilot Injection
2. Main Injection
In above two step injection, the fuel injection volume and injection timing is calibrated according to fuel pressure and
fuel temperature.

Pilot injection
Before starting main injection, a small amount of fuel is injected to help proper combustion. This injection is for
reducing the engine noise and vibration.
In other words, it makes the pressure increase in combustion chamber during combustion smooth to reduce the
engine noise and vibration (suppressing the surging). Basic values for pilot injection are adjusted according to
the coolant temperature and intake air pressure.
Cylinder pressure (p)

Needle lift (k)

Cylinder pressure (p)

Needle lift (k)

Angle of crankshaft Angle of crankshaft

<Characteristic Curve of Discharge without <Characteristic Curve of Discharge with

Pilot Injection> Pilot Injection>

FUEL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 07 45

Main injection

GENERAL
Actual output from engine is achieved by main injection.
The main injection determines the pilot injection has been occurred, then calculates the injection volume. Accel-
erator pedal sensor, engine rpm, coolant temperature, intake air temperature and atmospheric pressure are

ASSY
basic date to calculate the fuel injection volume in main injection.

HOUSING
EXHAUST I N T A K E
1. Pilot injection
Pressure

2. Main injection
1a. Ignition pressure with pilot injection
2a. Ignition pressure without pilot injection

LUB
Angle of crankshaft

<Characteristic Curve of Combustion Chamber Pressure During Pilot Injection>

COOLING
FUEL
CONTROL
SENSOR

CHANGED BY FUEL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
46 07

Removal and Installation

Preceding Work: Removal of engine cover

1. Disconnect the injector return hose.

NOTICE
• Plug the openings with sealing caps.

2. Remove the relevant connector for the injector.

3. Unscrew the bolts and remove the fuel pipes.

Installation Notice
Tightening torque 40 ± 4 Nm

NOTICE
• Replace the fuel pipes with new ones.
• Plug the openings of the common rail with sealing
caps.

4. Unscrew the injector holder bolts.

Installation Notice
9 ± 1.0 Nm
Tightening torque
190° + 10°

Replace the bolts with new ones.

5. Disconnect the injector holder.

6. Remove the injectors with a special tool.

NOTICE
• Plug the openings of the injectors with sealing caps.
• Pull the dropped washer out from the engine with
a special tool.

7. Install in the reverse order of removal.

NOTICE
• Replace the copper washer, holder bolts and fuel
supply pipes with new ones.

FUEL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 07 47

Circuit Diagram

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY FUEL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
48 07

FUEL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 07 49

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY FUEL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
 MEMO
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ENGINE CONTROL SYSTEM
08

TABLE OF CONTENTS
SENSORS FOR DIAGNOSIS .................................. 2
Engineecu and other components ..............................................2
Top view .....................................................................................3
Side view ................................................................................... 4

ENGINE CONTROL SYSTEM ................................. 5

ECU ...........................................................................................5
Fuel pressure control ............................................................... 11
Fuel injection control ................................................................ 12
Fuel flow control ....................................................................... 13
Individual Injector calibration (C2I) ............................................ 18
Minimum drive pulse (MDP) learning ........................................ 20
 2

Coolant inlet hose Coolant Port

08

ACTYON SM - 2006.03
Coolant reservoir

Return hose
Coolant

ENGINE CONTROL SYSTEM

outlet
port

Coolant outlet hose

Engine Oil Filter and Cooler

Oil cooler
SENSORS FOR DIAGNOSIS

Oil Filter
cap
ENGINE ECU AND OTHER COMPONENTS

Radiator Oil
pressure
switch
Water Pump and Pipe

Thermostat (inside)
Cylinder block

Oil cooler Oil filter

CHANGED BY

AFFECTED VIN
Radiator

EFFECTIVE DATE
Reservior (coolant
inlet hose)
 08 3

TOP VIEW

GENERAL
Fuel Pressure Sensor Booster Pressure Sensor

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

Injectors (4 EA) Glow Plugs (4 EA)

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
4 08

SIDE VIEW

Coolant Temperature Knock Sensors (1 EA)

Sensor

Fuel Pressure Crankshaft Position

Fuel Temperature Sensor
Regulating Valve Sensor

ENGINE CONTROL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 5

ENGINE CONTROL SYSTEM

GENERAL
ECU

ASSY
According to input signals from various sensors, engine ECU calculates driver’s demand (position of the accelerator
pedal) and then controls overall operating performance of engine and vehicle on that time.
ECU receives signals from sensors through data line and then performs effective engine air-fuel ratio controls based

HOUSING
on those signals.
Engine speed is measured by crankshaft speed (position) sensor and camshaft speed (position) sensor determines
injection order and ECU detects driver’s pedal position (driver’s demand) through electrical signal that generated by
variable resistance changes in accelerator pedal sensor.

EXHAUST I N T A K E
Air flow (hot film) sensor detects intake air volume and then transmits to ECU. Especially, the engine ECU controls
the air-fuel ratio by recognizing instant air volume changes through air flow sensor to pursue low emission gases
(EGR valve control). Furthermore, the ECU uses signals from coolant temperature and air temperature sensor,
booster pressure sensor and atmospheric pressure sensor as compensation signal to respond to injection start and
pilot injection set values and to various operations and variables.

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
6 08

Pin No. Description Pin No. Description

1 Engine ground 40 Fuel filter water detection sensor
2 Engine ground 41 RPM signal output
3 Main power (IG 1) 42
4 Main power (IG 1) 43
5 Main power (IG 1) 44 Knock sensor signal (#2)
6 Rail pressure sensor power supply 45 Knock sensor signal (#1)
7 46 Knock sensor ground (#1)
8 47
9 ECU power hold relay 48
10 49
11 50 Auto cruise result signal
12 ABD signal 51
13 52
14 ACC 2 sensor ground 53 ACC 1 sensor ground
15 54 CAN- H1
16 55
17 Auto cruise OFF 56
18 Auto cruise safety switch 57 ACC 2 sensor power supply
19 A/C pressure signal 58 Brake lamp switch
20 Fuel filter water detection warning lamp 59
21 Remote starter output 60 Vehicle speed indication lamp
22 Glow plug control 61 Preheater #1
23 Glow plug warning lamp 62 Preheater #2
24 63 Knock sensor ground (#2)
25 Rail pressure sensor signal 64 HFM sensor (air temperature sensor)
26 Rail pressure sensor ground 65
27 66 Engine ground
28 Engine ground 67 Auto cruise deceleration signal
29 68
30 69
31 Auto cruise acceleration signal 70
32 ACC 2 sensor signal 71 ACC 1 sensor signal
33 72 ACC 1 sensor power supply
34 K-LINE #1 73 CAN -LO
35 K-LINE #2 74
36 Vehicle speed sensor signal input 75
37 IG 1 76 A/C cycling pressure switch
38 Clutch pedal switch 77 Brake pedal switch
39 78 Trip computer

ENGINE CONTROL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 7

Pin No. Description Pin No. Description

GENERAL
79 A/C relay 101 Coolant temperature signal
80 Cooling fan LOW 102 Coolant temperature sensor ground
81 Cooling fan HIGH 103 Camshaft position sensor signal

ASSY
82 Crankshaft position sensor (-) 104 Camshaft position sensor ground
83 HFM sensor (air mass sensor) 105 Engine check warning lamp

HOUSING
84 HFM sensor (ground) 106
85 107 Blower switch
86 HFM sensor (power supply) 108 Booster pressure sensor power supply

EXHAUST I N T A K E
87 IMV (fuel pressure regulating valve) 109 Fuel temperature sensor signal
88 Engine ground 110 Fuel temperature sensor ground
89 111 Camshaft position sensor power supply
90 Crankshaft position sensor (+) 112 Immobilizer
91 113 Engine check warning lamp
92 114 Injector #1

LUB
93 115 Injector #4
94 116 Injector #3
95 Waste gate actuator 117 Injector ground (#1, 3, 4)

COOLING
96 EGR valve 118 Injector ground (#2, 5)
97 119
98 120 Injector #5

FUEL
99 Booster pressure sensor signal 121 Injector #2
100 Booster pressure sensor ground

CONTROL
SENSOR

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
8 08

ECU Inputs·Outputs

Inputs Control Output

Booster pressure sensor

Atmospheric pressure sensor Injector
(Built-in ECU) EGR system
Air flow sensor (HFM) Fuel pressure regulating valve (IMV)
Coolant temperature sensor Electrical fan control (Low/High-speed)
Fuel temperature sensor E A/C compressor relay
Fuel pressure sensor Glow plug relay
Fuel filter water sensor Immobilizer
Knock sensor
C Warning lights
crankshaft position sensor (Water warning light, glow plug
camshaft position sensor
U indicator light, engine warning light)
Accelerator sensor Preheater (auxiliary heater)
Vehicle speed sensor K - line
Switch input signal CAN communication
(IG, brake, clutch, A/C signal, A/C Self-diagnosis
compressor)

Structure and Function of ECU

Function of ECU
ECU receives and analyzes signals from various sensors and then modifies those signals into permissible voltage
levels and analyzes to control respective actuators.
ECU microprocessor calculates injection period and injection timing proper for engine piston speed and crankshaft
angle based on input data and stored specific map to control the engine power and emission gas.
Output signal of the ECU microprocessor drives pressure control valve to control the rail pressure and activates
injector solenoid valve to control the fuel injection period and injection timing; so controls various actuators in
response to engine changes. Auxiliary function of ECU has adopted to reduce emission gas, improve fuel
economy and enhance safety, comforts and conveniences. For example, there are EGR, booster pressure
control, autocruise (export only) and immobilizer and adopted CAN communication to exchange data among
electrical systems (automatic T/M and brake system) in the vehicle fluently. And Scanner can be used to
diagnose vehicle status and defectives.
Operating temperature range of ECU is normally -40 ~ +85°C and protected from factors like oil, water and electro-
magnetism and there should be no mechanical shocks.
To control the fuel volume precisely under repeated injections, high current should be applied instantly so there is
injector drive circuit in the ECU to generate necessary current during injector drive stages.
Current control circuit divides current applying time (injection time) into full-in-current-phase and hold-current-phase
and then the injectors should work very correctly under every working condition.

ENGINE CONTROL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 9

Control Function of ECU

GENERAL
1. Controls by operating stages
: To make optimum combustion under every operating stage, ECU should calculate proper injection volume in
each stage by considering various factors.

ASSY
2. Starting injection volume control
: During initial starting, injecting fuel volume will be calculated by function of temperature and engine cranking
speed.

HOUSING
Starting injection continues from when the ignition switch is turned to ignition position to till the engine reaches
to allowable minimum speed.
3. Driving mode control

EXHAUST I N T A K E
: If the vehicle runs normally, fuel injection volume will be calculated by accelerator pedal travel and engine rpm
and the drive map will be used to match the drivers inputs with optimum engine power.

LUB
COOLING
FUEL
CONTROL
SENSOR

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
10 08

ECU - Removal and Installation

1. Flip up the front passenger’s seat and remove the ECU

cover nuts.
2. Remove the ECU bracket nuts.

3. Unscrew the ECU connect bolt and remove the ECU

assembly.

4. Install in the reverse order of removal.

5. Backup the below data with Scan-i when replacing
the ECU.
1) Current ECU data
2) Vehicle Identification Number (VIN)
3) Variant coding data
4) Then, input the data into new ECU. For immobilizer
equipped vehicle, additional coding operation is
necessary.

ENGINE CONTROL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 11

FUEL PRESSURE CONTROL

GENERAL
Fuel Pressure Control Elements
Pressure control consists of 2 principle modules.

ASSY
1. Determines rail pressure according to engine operating conditions.
2. Controls IMV to make the rail pressure to reach to the required value.
Pressure in the fuel rail is determined according to engine speed and load on the engine. The aim is to adapt the

HOUSING
injection pressure to the engine’s requirements.
1. When engine speed and load are high
: The degree of turbulence is very great and the fuel can be injected at very high pressure in order to optimize

EXHAUST I N T A K E
combustion.
2. When engine speed and load are low
: The degree of turbulence is low. If injection pressure is too high, the nozzle’s penetration will be excessive and
part of the fuel will be sprayed directly onto the sides of the cylinder, causing incomplete combustion. So there
occurs smoke and damages engine durability.
Fuel pressure is corrected according to air temperature, coolant temperature and atmospheric pressure and to take
account of the added ignition time caused by cold running or by high altitude driving. A special pressure demand is

LUB
necessary in order to obtain the additional flow required during starts. This demand is determined according to
injected fuel and coolant temperature.

Fuel Pressure Control

COOLING
Rail pressure is controlled by closed loop regulation of IMV. A mapping system – open loop – determines the current
which needs to be sent to the actuator in order to obtain the flow demanded by the ECU. The closed loop will correct
the current value depending on the difference between the pressure demand and the pressure measured.

FUEL
1. If the pressure is lower than the demand, current is reduced so that the fuel sent to the high pressure pump is
increased.
2. If the pressure is higher than the demand, current is increased so that the fuel sent to the high pressure pump is

CONTROL
reduced.

SENSOR
Flow demand
IMV current
Open

Engine speed
IMV

Current
Rail pressure
demand

Error PIG
governor
Correction

Measured rail
pressure

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
12 08

FUEL INJECTION CONTROL

Fuel Injection Control
Injection control is used in order to determine the characteristics of the pulse which is sent to the injectors.
Injection control consists as below.
1. Injection timing
2. Injection volume
3. Translating fuel injection timing and injection volume into values which can be interpreted by the injector driver.
1) a reference tooth (CTP)
2) the delay between this tooth and the start of the pulse (Toff)
3) the pulse time (Ton)

Main injection timing control

The pulse necessary for the main injection is determined as a function of the engine speed and of the injected flow.
The elements are;
1. A first correction is made according to the air and coolant temperatures.
This correction makes it possible to adapt the timing to the operating temperature of the engine. When the engine
is warm, the timing can be retarded to reduce the combustion temperature and polluting emissions (NOx). When
the engine is cold, the timing advance must be sufficient to allow the combustion to begin correctly.
2. A second correction is made according to the atmospheric pressure.
This correction is used to adapt the timing advance as a function of the atmospheric pressure and therefore the altitude.
3. A third correction is made according to the coolant temperature and the time which has passed since starting.
This correction allows the injection timing advance to be increased while the engine is warming up (initial 30
seconds). The purpose of this correction is to reduce the misfiring and instabilities which are liable to occur after
a cold start.
4. A fourth correction is made according to the pressure error.
This correction is used to reduce the injection timing advance when the pressure in the rail is higher than the
pressure demand.
5. A fifth correction is made according to the rate of EGR.
This correction is used to correct the injection timing advance as a function of the rate of exhaust gas recirculation.
When the EGR rate increases, the injection timing advance must in fact be increased in order to compensate for
the fall in termperature in the cylinder.
During starting, the injection timing must be retarded in order to position the start of combustion close to the TDC.
To do this, special mapping is used to determine the injection timing advance as a function of the engine speed and
of the water temperature. This requirement only concerns the starting phase, since once the engine has started the
system must re-use the mapping and the corrections described previously.

Pilot injection timing control

The pilot injection timing is determined as a function of the engine speed and of the total flow.
The elements are;
1. A first correction is made according to the air and coolant temperatures.
This correction allows the pilot injection timing to be adapted to the operating temperature of the engine.
2. A second correction is made according to the atmospheric pressure.
This correction is used to adapt the pilot injection timing as a function of the atmospheric pressure and therefore
the altitude.
During the starting phase, the pilot injection timing is determined as a function of the engine speed and of the coolant
temperature.
ENGINE CONTROL SYSTEM CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 13

FUEL FLOW CONTROL

GENERAL
Main Flow Control
The main flow represents the amount of fuel injected into the cylinder during the main injection. The pilot flow

ASSY
represents the amount of fuel injected during the pilot injection.
The total fuel injected during 1 cycle (main flow + pilot flow) is determined in the following manner.
: The driver’s demand is compared with the value of the minimum flow determined by the idle speed controller.

HOUSING
1. When the driver depress the pedal, it is his demand which is taken into account by the system in order to
determine the fuel injected.
2. When the driver release the pedal, the idle speed controller takes over to determine the minimum fuel which must

EXHAUST I N T A K E
be injected into the cylinder to prevent the enigne from stalling.
It is therefore the greater of these 2 values which is retained by the system. This value is then compared with the
lower flow limit determined by the ASR trajectory control system. As soon as the injected fuel becomes lower than
the flow limit determined by the ASR trajectory control system, the antagonistic torque (engine brake) transmitted to
the drive wheels exceeds the adherence capacity of the vehicle and there is therefore a risk of the drive wheels
locking. The system thus chooses the greater of these 2 values (main flow & pilot flow) in order to prevent any loss
of control of the vehicle during a sharp deceleration.
This value is then compared with the flow limit determined by the cruise control. As soon as the injected fuel

LUB
becomes lower than the flow limit determined by the cruise control, the vehicle’s speed falls below the value required
by the driver. The system therefore chooses the greater of these 2 values in order to maintain the speed at the
required level.

COOLING
This valve is then compared with the flow limit determined by the flow limitation strategy. This strategy allows the
flow to be limited as a function of the operating conditions of the engine. The system therefore chooses the smaller
of these 2 values in order to protect the engine. This value is then compared with the fuel limit determined by the ASR
trajectory control system.

FUEL
As soon as the injected fuel becomes higher than the fuel limit determined by the ASR trajectory control system, the
engine torque transmitted to the wheels exceeds the adhesion capacity of the vehicle and there is a risk of the drive
wheels skidding. The system therefore chooses the smaller of the two values in order to avoid any loss of control of

CONTROL
the vehicle during accelerations.

The anti-oscillation strategy makes it possible to compensate for fluctuations in engine speed during transient

SENSOR
conditions. This strategy leads to a fuel correction which is added to the total fuel of each cylinder. The correction is
determined before each injection as a function of the instantaneous engine speed.

A switch makes it possible to change over from the supercharge fuel to the total fuel according to the state of the
engine.
1. Until the stating phase has finished, the system uses the supercharged fuel.
2. Once the engine changes to normal operation, the system uses the total fuel.

The main fuel is obtained by subtracting the pilot injection fuel from the total fuel.
A mapping determines the minimum fuel which can control an injector as a function of the rail pressure. As soon as
the main fuel falls below this value, the fuel demand changes to 0 because in any case the injector is not capable of
injecting the quantity demand.

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
14 08

Driver’s request

Idle speed controller

ASR traction control

Cruise control

Flow limit

Speed limiter

ASR traction control

Engine status

Anti-oscillation
strategy

Overflow

Programmed engine
stop
Main flow < controllable min.flow

Pilot injection flow

Main flow request
0

Driver Demand
The driver demand is the translation of the pedal position into the fuel demand. It is calculated as a function of the
pedal position and of the engine speed. The driver demand is filtered in order to limit the hesitations caused by rapid
changes of the pedal position. A mapping determines the maximum fuel which can be injected as a function of the
driver demand and the rail pressure. Since the flow is proportional to the injection time and to the square root of the
injection pressure, it is necessary to limit the flow according to the pressure in order to avoid extending the injection
for too long into the engine cycle. The system compares the driver demand with this limit and chooses the smaller
of the 2 values. The driver demand is then corrected according to the coolant temperature. This correction is added
to the driver demand.

ENGINE CONTROL SYSTEM CHANGED BY

ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 08 15

Idle Speed Controller

GENERAL
The idle speed controller consists of 2 principal modules:
1. The first module determines the required idle speed according to:
1) The operating conditions of the engine (coolant temperature, gear engaged)

ASSY
2) Any activation of the electrical consumers (power steering, air conditioning, others)
3) The battery voltage

HOUSING
4) The presence of any faults liable to interface with the rail pressure control or the injection control. In this case,
the accelerated idle speed is activated to prevent the engine from stalling when operating in degraded mode.
5) It is possible to increase or to reduce the required idle speed with the aid of the diagnostic tool.
2. The second module is responsible for providing closed loop control of the engine’s idle speed by adapting the

EXHAUST I N T A K E
minimum fuel according to the difference between the required idle speed and the engine speed.

Flow Limitation
The flow limitation strategy is based on the following strategies:
1. The flow limitation depending on the filling of the engine with air is determined according to the engine speed and
the air flow. This limitation allows smoke emissions to be reduced during stabilized running.

LUB
2. The flow limitation depending on the atmospheric pressure is determined according to the engine speed and the
atmospheric pressure. It allows smoke emissions to be reduced when driving at altitude.
3. The full load flow curve is determined according to the gear engaged and the engine speed. It allows the maximum

COOLING
torque delivered by the engine to be limited.
4. A performance limitation is introduced if faults liable to upset the rail pressure control or the injection control are
detected by the system. In this case, and depending on the gravity of the fault, the system activates:

FUEL
1) Reduced fuel logic 1: Guarantees 75 % of the performance without limiting the engine speed.
2) Reduced fuel logic 2: Guarantees 50 % of the performance with the engine speed limited to 3,000 rpm.
3) Reduce fuel logic 3: Limits the engine speed to 2,000 rpm.

CONTROL
The system chooses the lowest of all these values.
A correction depending on the coolant temperature is added to the flow limitation. This correction makes it possible
to reduce the mechanical stresses while the engine is warming up. The correction is determined according to the
coolant temperature, the engine speed and the time which has passed since starting.

SENSOR
Superchager Flow Demand
The supercharge flow is calculated according to the engine speed and the coolant temperature. A correction depend-
ing on the air temperature and the atmospheric pressure is made in order to increase the supercharge flow during
cold starts. It is possible to alter the supercharge flow value by adding a flow offset with the aid of the diagnostic tool.

CHANGED BY ENGINE CONTROL SYSTEM

EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
16 08

Pilot Flow Control

The pilot flow represents the amount of fuel injected into the cylinder during the pilot injection. This amount is
determined according to the engine speed and the total flow.
1. A first correction is made according to the air and water temperature.
This correction allows the pilot flow to be adapted to the operating temperature of the engine. When the engine is
warm, the ignition time decreases because the end-of-compression temperature is higher. The pilot flow can
therefore be reduced because there is obviously less combustion noise when the engine is warm.
2. A second correction is made according to the atmospheric pressure.
This correction is used to adapt the pilot flow according to the atmospheric pressure and therefore the altitude.
During starting, the pilot flow is determined on the basis of the engine speed and the coolant temperature.

Cylinder Balancing Strategy

Balancing of the point to point flows
The pulse of each injector is corrected according to the difference in instantaneous speed measured between 2
successive injectors.
1. The instantaneous speeds on two successive injections are first calculated.
2. The difference between these two instantaneous speeds is then calculated.
3. Finally, the time to be added to the main injection pulse for the different injectors is determined. For each
injector, this time is calculated according to the initial offset of the injector and the instantaneous speed difference.

Detection of an injector which has stuck closed

The cylinder balancing strategy also allows the detection of an injector which has stuck closed. The difference in
instantaneous speed between 2 successive injections then exceeds a predefined threshold. In this case, a fault is
signaled by the system.

Accelerometer Strategy
Resetting the pilot injection
The accelerometer is used to reset the pilot injection flow in closed loop for each injector. This method allows the
correction of any injector deviations over a period of time. The principle of use of the accelerometer is based on the
detection of the combustion noises.
The sensor is positioned in such a way as to receive the maximum signal for all the cylinders. The raw signals from
the accelerometer are processed to obtain a variable which quantifies the intensity of the combustion. This variable,
known as the ratio, consists of the ratio between the intensity of the background noise and the combustion noise.
1. A first window is used to establish the background noise level of the accelerometer signal for each cylinder. This
window must therefore be positioned at a moment when there cannot be any combustion.
2. The second window is used to measure the intensity of the pilot combustion. Its position is such that only the
combustion noises produced by the pilot injection are measured . It is therefore placed just before the main
injection.
The accelerometer does not allow any evaluation of the quantity injected. However, the pulse value will be measured
when the injector starts injection and this pulse value is called the MDP (Minimum Drive Pulse). On the basis of this
information, it is possible to efficiently correct the pilot flows. The pilot injection resetting principle therefore consists
of determining the MDP, in other words the pulse corresponding to the start of the increase in value of the ratio
(increase of vibration due to fuel combustion).

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GENERAL
Cylinder pressure
Needle lift

Major pilot injection Ratio

ASSY
Minor pilot injection

HOUSING
No pilot injection

EXHAUST I N T A K E
No injection

LUB
This is done periodically under certain operating conditions. When the resetting is finished, the new minimum pulse
value replaces the value obtained during the previous resetting. The first MDP value is provided by the C2I. Each

COOLING
resetting then allows the closed loop of the MDP to be updated according to the deviation of the injector.

Detection of leaks in the cylinders

The accelerometer is also used to detect any injector which may have stuck open. The detection principle is based
on monitoring the ratio. If there is a leak in the cylinder, the accumulated fuel self-ignites as soon as the temperature

FUEL
and pressure conditions are favorable (high engine speed, high load and small leak).
This combustion is set off at about 20 degrees before TDC and before main injection.

CONTROL
The ratio therefore increases considerably in the detection window. It is this increase which allows the leaks to be
detected. The threshold beyond which a fault is signaled is a percentage of the maximum possible value of the ratio.
Because of the severity of the recovery process (engine shut-down), the etection must be extremely robust.
An increase in the ratio can be the consequence of various causes:

SENSOR
1. Pilot injection too strong
2. Main combustion offset
3. Fuel leak in the cylinder
If the ratio becomes too high, the strategy initially restricts the pilot injection flow and retards the main injection. If
the ratio remains high despite these interventions, this shows that a real leak is present, a fault is signaled and the
engine is shut down.

Detection of an accelerometer fault

This strategy permits the detection of a fault in the sensor or in the wiring loom connecting the sensor to the ECU.
It is based on detection of the combustion. When the engine is idling, the detection window is set too low for the
combustion caused by the main injection. If the ratio increases, this shows that the accelerometer is working
properly, but otherwise a fault is signaled to indicate a sensor failure. The recovery modes associated with this fault
consist of inhibition of the pilot injection and discharge through the injectors.

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18 08

INDIVIDUAL INJECTOR CALIBRATION (C2I)

Injected fuel is proportional to square root of injection time and rail pressure.
It is function between pulse and rail pressure and fuel injection curve is called injector characteristics curve having
the following shape.
Delivery (mm3/st)

Drive pulse (µsec)

Common rail injectors are very accurate components. They are able to inject fuel delivery between 0.5 to 100 mg/str
under pressure varying from 150 to 1600 bar.
This high level of accuracy requires very low machining tolerances (few ).
Nevertheless, due to the machining dispersion, the loss of charge through the functional orifices, the friction between
moving parts and electromagnetic field level are different from one injector to the other. So, the difference of fuel
delivery for the same pressure and the same pulse can reach 5 mg/str from one injector to the other. It is impossible
to control efficiently the engine with such a dispersion between the different injectors. It is necessary to add a
correction that allows injecting the demanded fuel delivery whatever the initial hydraulic characteristics of the injector
is. The method consists in correcting the pulse that is applied to the injector with an offset that depends on the initial
hydraulic map of the injector. So, the pulse should be corrected according to characteristics of each injector.

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C2I is composed of models on these characteristics of injectors.

GENERAL
C2I consists of 16-digit; composed of numbers from 1 to 9 and alphabets from A to F. ECU remembers C2I,
characteristics of each injector, to make the most optimal fuel injection.
1. When replacing the injector, C2I code on the top of new injector should be input into ECU because the ECU is

ASSY
remembering the injector’s C2I value. If C2I is not input, engine power drops and occurs irregular combustion.
2. When ECU is replaced, C2I code of every injector should be input. If not, cannot accelerate the vehicle even when
the accelerator pedal is depressed.

HOUSING
EXHAUST I N T A K E
LUB
C2I Number

COOLING
(16 digits)

C2I

FUEL
value

CONTROL
For coding of C2I, refer to “Diagnosis” section

SENSOR

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20 08

MINIMUM DRIVE PULSE (MDP) LEARNING

When the pulse value that the injector starts injection is measured, it is called mininum drive pulse (MDP). Through
MDP controls, can correct pilot injections effectively. Pilot injection volume is very small, 1 ~ 2 mm/str, so precise
control of the injector can be difficult if it gets old. So there needs MDP learning to control the very small volume
precisely through learning according to getting older injectors.

Learning Conditions
Coolant temperature > 75°C
Vehicle speed > 50 Km/h (over 5 seconds)
Intake manifold pressure > 0.7 bar
Engine speed > 2,500 rpm
Battery voltage 10 V < MDP < 16 V
Fuel temperature 0 < fuel temperature < 80 °C
Initial MDP learning on each injector 5 seconds

Trouble Codes
Trouble code Description Diagnosis
P1171 Fault MDP learning on injector No. 1
P1172 Fault MDP learning on injector No. 2
P1173 Fault MDP learning on injector No. 3 • Check each injector
P1174 Fault MDP learning on injector No. 4
P1175 Fault MDP learning on injector No. 5

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 08 21

Accelerator Pedal Sensor

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
<Location of Accelerator Pedal Sensor> <When Depressing the Accelerator Pedal and
Brake Pedal Simultaneously>

LUB
Accelerator pedal sensor changes accelerator pedal position into electrical signal and then sends to ECU to let
know the driver’s demand. There are 2 sensors in the accelerator pedal sensor. Accelerator pedal No.1 (ACC 1)
sensor signal determines fuel injection volume and injection timing during driving, and accelerator pedal No. 2 (ACC

COOLING
2) sensor signal compares whether the No. 1 sensor signal value is correct.
If accelerator pedal No. 1 and 2 sensors are defective, ECU remembers defect code, and acceleration responses are
getting bad and engine rpm hardly increases.

FUEL
NOTICE
• When depressing the accelerator pedal and brake pedal simultaneously while driving, the acceleration
response will be diminished abruptly and cannot drive with over 70 km/h even though depressing the

CONTROL
accelerator pedal to its end. At this time, the trouble code of “P-1124 Accelerator pedal sensor stuck” is
stored into ECU. If depressing the accelerator pedal over 3 times, it will be resumed to normal condition.
• For detailed information, refer to “Diagnosis” section in this manual.

SENSOR
2

4
Signal 1

3
A/PEDAL Ground
SENSOR
1

6 Signal 2

5 Ground

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22 08

Coolant Temperature Sensor

Temp.

Resistance
<Coolant Temperature Sensor> <Output Characteristics of Coolant
Temperature Sensor>

Coolant temperature sensor is a NTC resister that sends coolant temperature to ECU.
NTC resister has characteristics that if the engine temperature rises, the resistance lowers so the ECU detects
lowering signal voltages.
If the fuel injected into the engine through injector has more turbulence, then combusts very well. However, if engine
temperature is too low, the fuel injected as foggy state forms big compounds causing incomplete combustion. So
the sensor detects coolant temperature and changes coolant temperature changes into voltage then sends to ECU
to increase the fuel volume during cold start for better starting. And detects engine overheating for fuel volume
reduction to protect the engine.
ECU functions as below with coolant temperature sensor signals.
1. When engine is cold, controls fuel volume to correct idle speed.
2. When engine is overheated, controls electrical fan and A/C compressor to protect the engine.
3. Sends information for emission control.
Temperature (°C) Ω)
NTC 1 Resistance (Ω Ω)
NTC 2 Resistance (Ω
20 2,449 6,062
50 826 1,800
80 321 638
120 123 200

Signal

Auto amp

Ground

<Circuit Diagram of Coolant Temperature Sensor>

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 08 23

Boost Pressure Sensor

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
<Location of Boost Pressure Sensor>

Not using terminals

LUB
<Boost Pressure Sensor>

COOLING
Boost pressure sensor uses piezo element and uses only 3 terminals out of 6.
It sets fuel injection timing and corrects fuel injection volume according to atmospheric pressure.
The other function is determining EGR operation stops.
1. Output voltage calculation

FUEL
VO = VS x ( P x 0.004 - 0.04)
Voltage (V)

VO : Output voltage
VS : Supply voltage

CONTROL
P : Applying voltage

SENSOR
Pressure (bar)

<Output Characteristics of Sensor>

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24 08

Performance proofing pressure range 20 ~ 250 KPa

Performance proofing temperature range - 40 ~ 110°C
Storage proofing temperature range - 40 ~ 125°C
Performance proofing supply voltage 4.85 ~ 5.35 V
Max. consuming current 10 mA (supply voltage at 5.35 V)
Responsibility TR 7ms
Tightening torque 10 Nm

Ground

REF 5V

SIG

<Circuit Diagram of Booster Pressure Sensor>

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 08 25

Vehicle Speed Sensor

GENERAL
The ABS or ESP control unit sends the vehicle speed signals to ECU. ECU uses these signals to calculate the
vehicle speed and meter cluster shows signals as vehicle speed.

Function

ASSY
1. Limits idle control correction duty range
2. Controls cooling fan ABS

HOUSING
or
3. Cuts fuel injection if exceeds max. speed
ESP control unit
4. Controls vehicle shifting feeling
5. Used for exhaust gas control mode
CAN communication

EXHAUST I N T A K E
LUB
COOLING
<Circuit Diagram of Vehicle Speed Sensor>

FUEL
Barometric Sensor
It is built-in the ECU and detects absolute pressure of atmosphere to correct fuel injection timing and injection

CONTROL
volume according to altitude.

SENSOR

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26 08

Other switches
Brake switch
Brake switch detects brake pedal operations and then sends to engine ECU. It has dual structure with 2 combined
switches and there are brake switch 1 and 2. When these 2 signals are input, engine ECU recognizes as normal
brake signals. These switch signals are related with accelerator pedal sensor operations and used to control the fuel
volume during braking. It means there are no problems in operating accelerator pedal when the brake pedal is
operated but the fuel volume reduces if operates brake pedal while the accelerator pedal is depressed.

Brake pedal switch (NC)

IGN 1

Brake lamp switch (NO)

<Brake Switch Circuit>

Clutch pedal switch

Clutch pedal switch is installed on the upper of the clutch and sends clutch pedal operations to engine ECU. Contact
type switch allows engine ECU to recognize the shifting points to correct the fuel volume. It means it corrects
fluctuation happens during gear shifting. Another different function is canceling auto cruise function if equipped (auto
cruise control - equipped for export).

Clutch pedal switch (NO)

Engine 2 1
ground

<Clutch Pedal Switch Circuit>

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ELECTRIC DEVICES
AND SENSORS
09

TABLE OF CONTENTS
ELECTRIC DEVICES AND SENSORS................... 2
Sensors in engine compartment ................................................2
Electric devices in engine compartment .....................................3
Specifications ............................................................................4
Circuit diagram of preheating system ......................................... 5
Circuit diagram of starting and alternator ................................... 6

TROUBLE DIAGNOSIS ........................................... 7

General ...................................................................................... 7
Alternator ................................................................................... 9
Starter ...................................................................................... 10
2 09

ELECTRIC DEVICES AND SENSORS

SENSORS IN ENGINE COMPARTMENT

Booster Pressure
Fuel Pressure Sensor Sensor

Camshaft Position
Sensor Oil Pressure Switch

Coolant Temperature Crankshaft Position

Sensor Sensor

Fuel Temperature
Knock Sensor (1 EA)
Sensor

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 09 3

ELECTRIC DEVICES IN ENGINE COMPARTMENT

GENERAL
ASSY
Alternator Glow Plug
Capacity
PTC equipped vehicle

HOUSING
: 12V - 140A
FFH equipped vehicle
: 12V - 115A

EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR
Air Conditioner Compressor Starter

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4 09

SPECIFICATIONS
Description Unit Specification
Starter Type - WP220
Output power Kw 2.2
No load test ≅ 12 volts A 160
Drive pinion speed at no load rpm 4500
Drive pinion speed at load rpm/A 1700/430
Brush length mm 18
Armature diameter mm 55
Armature run-out mm 0.1
Segment groove depth mm 21.7
Alternator Type - CS128D
Output voltage / current V/A PTC equipped vehicle: 12V-140A
FFH equipped vehicle: 12V-115A
Regulator type - ←
Regulating voltage V 14.6
Brush Length mm 12.5
Quantity - 2
Wear limit mm 7
Battery Type - MF
Capacity AH 12V - 90AH
Glow plug Reserved capatity RC 160
Type - Seized type
Rated voltage - 11.5
Circuit connection - Parallel
Preheating time sec Max. 60 (at -35°C)

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 09 5

CIRCUIT DIAGRAM OF PREHEATING SYSTEM

GENERAL
PREHEATING

ASSY
HOUSING
EXHAUST I N T A K E
LUB
COOLING
FUEL
CONTROL
SENSOR

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6 09

CIRCUIT DIAGRAM OF STARTING AND ALTERNATOR

STARTING & CHARGING

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 09 7

TROUBLE DIAGNOSIS

GENERAL
GENERAL

ASSY
Condition Probable Cause Correction
No crank • Low battery voltage. • Charging the battery or replace

HOUSING
the battery.
• Battery cable is loose, • Repair or replace the battery
corroded, or damaged. cable.
• Faulty starter motor or starter • Repair or replace the starter

EXHAUST I N T A K E
motor circuit is open. motor/starter motor circuit.
• Faulty ignition switch. • Replace the ignition switch.
• Ground short. • Repair the ground short.
Crank ok, but too slow • Low battery voltage. • Charging the battery or replace
the battery.
• Battery. • Repair or replace the battery
• Battery cables are loose, cable.

LUB
corroded, or damaged.
• Faulty starter motor. • Repair or replace the starter
motor.

COOLING
Starter motor does not stop • Faulty starter motor. • Repair or replace the starter
motor.
• Faulty ignition switch. • Replace the ignition switch.
• Broken the clutch pinion gear or • Replace the starter motor.

FUEL
Starter motor running, but not
cranking faulty starter motor.
• Broken the flywheel ring gear. • Replace the flywheel.

CONTROL
• Connected circuit is open. • Repair the open circuit.
Battery discharge • Loosen the generator drive belt. • Adjust the belt tension or
replace the belt.
• The circuit is open or a short. • Repair the open or a short circuit.

SENSOR
• Battery run down. • Replace the battery.
• Open ground circuit. • Repair the open ground circuit.
Charging indicator lamp does not • Charging indicator lamp is blown • Repair or replace the charging
work when the ignition switch on or fuse is blown. indicator lamp/fuse.
(engine does not work) • Faulty ignition switch. • Replace the ignition switch.
• Generator ground circuit is open • Repair the circuit.
or a short.
Charging indicator lamp does not • Battery cable is corroded or • Repair or replace the battery
put out lights after starting the damaged. cable.
engine • Loosen the generator drive belt. • Adjust the belt tension or
replace the belt.
• Faulty wiring harness. • Repair the wiring harness.
Battery over charging • Generator voltage regulator faulty • Replace generator
• Voltage detecfing wiring faulty • Repair wiring

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8 09

Symptom Cause Action

Hard engine starting • Ignition coil faulty • Replace ignition coil
• Distributor (including optical • Replace distribator (or sensor)
sensor) faulty
• Spark plug malfuntion • Replace spark plug or adjust
clearance
• Ignition timing faulty (spark plug • Resetting valve timing
light is normal)
Unstable engine idling • Spark plug malfunction • Replace spark plug or adjust
clearance
• Ignition coil faulty • Replace ignition coil
• Ignition timing faulty • Resetting valve timing
Enging acceralation malfunction • Ignition timing faulty • Resetting valve timing

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 09 9

ALTERNATOR

GENERAL
ASSY
HOUSING
EXHAUST I N T A K E
LUB
1. Cooling fan 3. Alternator

COOLING
2. Bolt ............................................................. 45 Nm 4. Plug connection

FUEL
Removal and Installation
1. Disconnect the negative battery cable.

CONTROL
2. Remove the plug connection.

SENSOR
3. Unscrew the bolts and remove the alternator.

Installation Notice
Tightening torque 45 Nm

4. Install in the reverse order of removal.

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10 09

STARTER

1. Starter 3. Nut .................................................................... 15 Nm

2. Washer 4. Bolt ................................................................... 48 Nm

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 09 11

GENERAL
Removal and Installation
1. Disconnect the negative battery cable.
2. Disconnect the starter terminal.

ASSY
HOUSING
EXHAUST I N T A K E
3. Lift up the vehicle and remove the front propeller shaft
mounting bolts.

LUB
COOLING
4. Remove the upper and lower mounting bolts.

FUEL
CONTROL
SENSOR
5. Install in the reverse order of removal.

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 MEMO
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 SCAN-100

TABLE OF CONTENTS
SCAN-100 GENERAL ..................................................................... 3

SCAN LOAD .................................................................................... 3

D-CARD DOWNLOAD .................................................................... 4

REPROGRAM .................................................................................. 8

ENTERING DIAGNOSIS PROCEDURES ................................... 28

FUNCTION SELECTION .............................................................. 30

 SCAN-100 3

SCAN-100 GENERAL

SCAN
SCAN LOAD

ECU
1. Introduction
This SCANLOAD program is designed to write an operating program to your program card of SCAN-100.

2. Installation
In order to install SCANLOAD, the previous requirements should be satisfied in your computer.
In addition, windows 98 also should be installed. If the windows configuration is not set up, Complete installing the
windows, and then follow the procedure of the below.

Screen Flow Description

Make a directory ”SCANLOAD” in hard disk. Copy a

given program, and execute a “setup.exe”.

Click the button , to install the program in

the target directory.

Execute the program, after finishing installing setup

program.

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4 SCAN-100

D-CARD DOWNLOAD

1. Connecting SCAN-100 to PC

1. AC/DC Power Supply

2. DC Power Jack
3. RS-232 communication cable
4. PC Terminal

2. Inserting Program Card into SCAN-100

1. Program Card Slot

2. Memory Card Slot
3. Hinged Body
4. Card Eject Button
5. Program Card
6. Notches

1. Inserting program card : Insert the card with label(SCAN-100 program card ver. ) side up and to the direction of
arrow. Push this card all the way to the end. And if the card is inserted in a wrong way, the card may not be set
in the slot.

2. “PCMCIA” cards and memory capacities.

PCMCIA card is consist of FLASH memory. SCAN-100 has two kinds of PCMCIA card; program card and data
memory card.

Program card: This card contains the operation program of SCAN-100.

Data memory card: This is used for recording a traveling data, a wave data, etc.
Capacities of program card: It is able to extend its memory capacity up to 16MByte, and its basic memory
is 2MByte.
Capacities of data memory card: It is able to extend its memory capacity up to 10MByte.

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 SCAN-100 5

3. Selecting Download Mode of SCAN-100

SCAN
1. Connect communication port of PC to left input port of
SCAN-100 by using a download communication cable.
2. Press “PWR” key after pushing a hotkey (“YES” + “NO”

ECU
+ “2”).
3. Perform a SCANLOAD program.

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6 SCAN-100

4. Perform Scanload

Screen Flow Description

Click the button , in an initial screen.

Select the communication port connected to SCAN-

100.

Basic screen of download mode.

Click the button .

Select a file which you wish to write, and click the

button .

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 SCAN-100 7

SCAN
Screen Flow Description

ECU
Click the button .

If the ID of a selecting file is same to the SCAN-100’s

ID, then is indicated. if not, then it shows

message.

Write a selecting file to program card of SCAN-100.

If the download is completed,

Then you get a message.

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8 SCAN-100

REPROGRAM
1. Reprogramming Flow Chart

Reprogramming data file provided from SYMC.

STEP I
(R-CARD reprogramming data)

Update the D-CARD program, if necessary

(PC to D-CARD)
STEP II
1. Refer to “SCANLOAD USER’S GUIDE” in supplied
CD-ROM inside SCAN-100 kit box.

Download the reprogramming data to the R-CARD

(PC to R-CARD)
STEP III 1. R-CARD DOWNLOAD (PC to SCAN-100) ... 2
2. R-CARD DATA ERASE (SCAN-100) ............ 6
3. R-CARD DATA VIEW (SCAN-100) ............... 6

Reprogramming the ECU (SCAN-100 to ECU)

STEP IV
1. ECU REPROGRAM (SCAN-100 to ECU) ..... 7

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 SCAN-100 9

2. R-Card Download (PC to SCAN-100)

SCAN
1. Check and see if the D-Card exist in the upper slot (Slot “A”) of SCAN-100.
2. Check and see if the R-Card exist in the lower slot (Slot “B”) of SCAN-100.
3. Connecting the SCAN-100 to PC

ECU
1. SCAN-100 AC/DC Power Supply
2. DC Power Jack
3. RS-232 Communication Cable
4. PC Terminal

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10 SCAN-100

4. Press the POWER ON the SCAN-100 and process the steps as below.

#1 #2

Select “1”

#4 #3

#5

(Fig. 1-1)

If your SCAN-100 display above screen (fig.1-1), please go to the next step.

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 SCAN-100 11

5. Select the file to be matched with your vehicle model and drag it onto the “KWPSEND.EXE” file.

SCAN
#7

ECU
6. Key-in the number of the COM PORT connected with SCAN-100 in the key board

#8

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12 SCAN-100

7. The SACN 100 shows below figure (Fig. 1-2) while successful downloading

#1 #2

Select “2”

(Fig. 1-2)

8. Repeat the Step 4 through Step 7 for downloading the reprogramming data of the other vehicle model.

No. VEHICLE MODEL FILE NAME VEHICLE STATUS

1 CHAIRMAN 2.3 NAG (A/T) DT1742G$.SYN T1
2 CHAIRMAN 2.3 BTRA (A/T) DZ1742G$.SYN Z1
3 CHAIRMAN 2.8 DF1742O$.SYN F1
4 CHAIRMAN 3.2 DG1742V$.SYN G1
5 REXTON 2.8 DI1742T$.SYN I1
6 REXTON 3.2 GENERAL AREA DH1742P$.SYN H1
7 REXTON 3.2 WESTERN EUROPE DH37427$.SYN H3
(EURO III REGULATION)
8 MUSSO/KORANDO 3.2 DS1742P$.SYN S1
GENERAL AREA
9 MUSSO/KORANDO 3.2 DS3742S$.SYN S3
WESTERN EUROPE
(EURO III REGULATION)
10 KYRON D20DT ECU HCC6AM01.SYN

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 SCAN-100 13

3. R-Card Data Erase (SCAN-100)

SCAN
This mode is to erase the data saved in R-CARD of SCAN-100
Input the number you want to erase directly or move the cursor to which you want to erase and press "ENTER" key.

ECU
It is possible data scroll using the “ , ” key.

4. R-Card Data View (SCAN-100)

This mode is to confirm data which is saved in R-CARD of SCAN-100.

It is possible data scroll using the “ , ” key.

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5. ECU Reprogram (SCAN-100 to ECU) - DSL

1. Check the vehicle to be reprogrammed.
2. Connect the SCAN-100 to the diagnostic connector of the vehicle.

#1 #2

Select “1”

#4 #3

after 1sec.

Check the ECU S/W Number

Next page

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 SCAN-100 15

Preceding page

SCAN
S/W Number: HCC6A

ECU
S/W Number: HCC63,
HCC67 or HCC69

#5

If the S/W Number is HCC6A,

Not necessary, already updated

after 1sec.

Select “6”

#6
Exit the ECU REPRORGRAMMING
PROCEDURE

after 1sec.

Next page

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Preceding page

Select “1”

#7 #8

ENTER

“Yes”

# 10 #9

ENTER

Input the reprogramming date

# 11 # 12

After
Finish

Next page

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 SCAN-100 17

Preceding page

SCAN
# 13

ECU
CAUTION
• Take care that do not power off and dis-
connect the scan tool when the boot block
is reprogrammed. ECU can be damaged.

If the target vehicle has the automatic

transmission, you have to select No. 1(Euro Ver.)
or No.2 (Non Euro Ver.)
If the target vehicle has the manual transmission,
you have to select No. 3 (Euro Ver.) or No.4 (Non
Euro Ver.)

Next page

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Preceding page

A/T Vehicle M/T Vehicle

# 14

A/T Vehicle M/T Vehicle

# 15 # 16

Press
“ESC”

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 SCAN-100 19

Preceding page

SCAN
With Immobilizer system Without Immobilizer
=> Press “ENTER” System => Press “ESC”

ECU
# 17

“Yes”

# 18

“Yes”

# 19

Next page Next page

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Preceding page Preceding page

# 20

“No”

# 22 # 21

“ENTER”

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 SCAN-100 21

6. ECU Reprogram (SCAN-100 to ECU) - GSL

SCAN
1. Check the vehicle to be reprogrammed.
2. Connect the SCAN-100 to the diagnostic connector of the vehicle.

ECU
#1 #2

Select “1”

after 1sec.

#3

Check the “Vehicle Status” is H1 or h1

Next page Next page

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22 SCAN-100

Preceding page Preceding page

#4

If vehicle status is H1 (Large Alphabet), start repro- If the vehicle status is h1 (Small Alphabet),
gram
DO NOT REPROGRAM !!!

#5
Exit the ECU REPRORGRAMMING
PROCEDURE

Next page

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 SCAN-100 23

Preceding page

SCAN
#6 #7

ECU
Select
Vehicle

It is possible data scroll using the “ , ” key.

05] MUSSO / KORANDO 3.2 ECU(RATIO) Select “Yes”

#9 #8

“ENTER”

Confirm the P/N of ECU and Reprogramming Input the reprogramming date

Date

ECU P/N
- CHAIRMAN 2.8 : 162 545 7532
- CHAIRMAN 3.2 : 162 545 7332
- REXTON 2.8 : 162 545 7932
- REXTON 3.2 : 162 545 5532
- MUSSO/KORNAND 3.2 : 162 545 6232

Select “Yes” Select “No”

Start to Reprogram Select the correct ECU version

Next page

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24 SCAN-100

Preceding page

# 10 # 11

After
Finish

(BOOT BLOCK REPROGRAM) (S/W BLOCK REPROGRAM)

CAUTION
• Take care that do not power off and dis-
connect the scan tool when the boot block
is reprogrammed. Error on boot block lead Reprogram OK
to replacement the ECU

# 13 # 12

Press Any
Key

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 SCAN-100 25

In Case of Unsuccessful (Not Good)

SCAN
CASE 1: Error when “The Boot Block” is reprogrammed.

ECU
CASE 2: Error when “The S/W Block” is reprogrammed.

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26 SCAN-100

In Case of Reprogram not Allowed.

CASE 1: When ECU is already reprogrammed.

“YES”

CASE 2: When Part Number(ECU S/W Type) is not same of ECU and selected data.

“YES”

When press “ESC” key, Return to main menu.

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 SCAN-100 27

Read ECU Identification

SCAN
ECU
Select “2”

VEHICLE STATUS
- CHAIRMAN 2.8 : F1
- CHAIRMAN 3.2 : G1
- REXTON 2.8 : I1
- REXTON 3.2 : H1
- MUSSO/KORNAND 3.2 : S1
Write VIN

Select “3”

Select “Yes”

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28 SCAN-100

ENTERING DIAGNOSIS PROCE-

DURES
1. Select “1] DIAGNOSIS” and press “ ” in “MAIN
MENU” screen.

2. Select “7] KYRON” and press “ ” in “VEHICLE

SELECTION” screen.

3. Select “1] ECU” and press “ ” in “CONTROL UNIT

SELECTION” screen.

4. Select “1] DSL D20DT" in [MODEL SELECTION] screen

and press “ ”.

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5. The “FUNCTION SELECTION” screen is displayed.

SCAN
ECU

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FUNCTION SELECTION
Check the Trouble Code
Preceding Work: Perform the “Entering Diagnosis
Procedures”

1. Select “1] TROUBLE CODE” and press “ENTER” in

“FUNCTION SELECTION” screen.

2. The “DIAGNOSTIC TROUBLE CODEs” screen is

displayed and it shows the trouble.

NOTE
• If there is not any fault, “NO TROUBLE DETECTED”
message appears.

3. When selecting a trouble code, then

if you press “ ”: Displays the sensor data for the
detected trouble (Freeze Frame
Mode).
if you press “ ”: Displays the help tips for the
detected trouble.

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 SCAN-100 31

Sensor Data Check

SCAN
Preceding Work: Perform the “Entering Diagnosis
Procedures”

ECU
1. Select “2] DATA LIST” and press “ ” in “FUNCTION
SELECTION” screen.

2. The screen shows approx. 57 sensor data.

3. Select the items you want to see and press “ ”

key to freeze them.

NOTE
• You can freeze up to 5 items (*: selected items).

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32 SCAN-100

Actuator Check
Preceding Work: Perform the “Entering Diagnosis
Procedures”

1. Select “3] ACTUATOR” and press “ ” in “FUNCTION

SELECTION” screen.

2. The screen shows 19 items. Select the item you want

to see and press “ ”.

3. For example, if you select “02] GLOW PLUG” item

and press “ ”, the screen as shown in figure is
displayed.

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 SCAN-100 33

4. If you want to operate the glow plug relay, press

SCAN
“ ” key. The “ACTIVATING” message appears and
the relay operation alarm sounds.

ECU
5. If the system operates normally, Scan-100 displays
“GOOD”.

6. If you want to stop the operation press “ ” key in

keyboard.

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34 SCAN-100

Trouble Code Clear

Preceding Work: Perform the “Entering Diagnosis
Procedures”

1. Select “1] TROUBLE CODE” and press “ ” in

“FUNCTION SELECTION” screen.

2. The “DIAGNOSTIC TROUBLE CODEs” screen is

displayed and it shows the trouble.

NOTE
• C = Current trouble, H = History trouble

3. Fix the trouble and go back to “1] TROUBLE CODE”

screen and check if the trouble has been changed
to “H (History trouble code)” code.

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 SCAN-100 35

4. If the trouble has been change to “H (History trouble

SCAN
code)” code, press “ ” key to go back to “FUNCTION
SELECTION” screen. In this screen, select “4] TROUBLE
CODE CLEAR” and press “ ”.

ECU
5. The “TROUBLE CODE CLEAR” screen is displayed.
If you press “ ”, only the history trouble codes
will be cleared.

NOTE
• Current trouble codes will not be cleared.
• Check the trouble codes after clearing the trouble
codes.

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36 SCAN-100

ECU Identification
Preceding Work: Perform the “Entering Diagnosis
Procedures”

1. Select “5] ECU IDENTIFICATION” and press “ ”

in “FUNCTION SELECTION” screen.

2. The “ECU IDENTIFICATION” screen that shows the

VIN, ECU software number, ECU software version
and programming date is displayed.

3. If you replaced the ECU, press “ ” to input the

vehicle identification number.

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 SCAN-100 37

Injector (C2I) Corrections

SCAN
Preceding Work: Perform the “Entering Diagnosis
Procedures”

ECU
NOTICE
• If the injector/ECU has been replaced or the injec-
tor system defective is suspected, go to C2I Cod-
ing item and check the injector and coded injector
C2I value.

1. Select “6] INJECTOR (C2I) CORRECTIONS” and

press “ ” in “FUNCTION SELECTION” screen.

2. The “INJECTOR (C2I) CORRECTIONS” screen that

shows current C2I coding values of #1 to #4 injector is
displayed.

3. If you replaced the ECU, enter the C2I value of the

relevant injector.

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38 SCAN-100

NOTE
• The C2I value of replacing injector is recorded in
the label.
• C2I coding number: 16 digits (ex, B1 B9 D4 1B 43
C6 0E 4F)

1) If you enter the invalid C2I value of the relevant

injector, the message as shown in figure appears
with alarm sound.

NOTE
• If you want to go back to previous screen, press
“ ” key. You can see the previous C2I value.

2) If you enter the valid C2I value of the relevant

injector, the message as shown in figure appears
with alarm sound.

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 SCAN-100 39

Leak Detection

SCAN
Preceding Work: Perform the “Entering Diagnosis
Procedures”

ECU
NOTE
• This item is for checking the high fuel pressure af-
ter the IMV supply line of HP pump in DI engine fuel
system. If you still suspect that the fuel pressure
system is defective even after no trouble is
detected, perform the fuel pressure test again by
using a fuel pressure tool kit.

1. Select “1] LEAK DETECTION” and press “ ” in

“FUNCTION SELECTION” screen.

2. The “LEAK DETECTION” screen that shows the

checking conditions as shown in figure is displayed.

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40 SCAN-100

Preceding page

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 SCAN-100 41

Variant Coding

SCAN
Preceding Work: Perform the “Entering Diagnosis
Procedures”

ECU
1. Select “8] VARIANT CODING” and press “ ” in
“FUNCTION SELECTION” screen.

2. When the “VARIANT CODING” screen is displayed,

select “1] READ VARIANT VALUE” and press “ ”.

3. Select “1] ENGINE VARIANT CODING” and press

“ ” in “FUNCTION SELECTION” screen.

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42 SCAN-100

4. The “VARIANT CODING” screen that shows currently

equipped devices is displayed.

ENGINE

CHASSIS

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 SCAN-100 43

SCAN
Engine Related Coding Item

Variant Coding Item Selection Description

ECU coding completed NO/YES “ ” is automatically selected.

ECU
Supplementary heater NO/YES Select “ ” only for the vehicle with PTC type supple-
(PTC) mentary heater (in DI engine).

Auto cruise NO/YES Select “ ” only for the vehicle with auto cruise system.

Immobilizer NO/YES Select “ ” only for the vehicle with immobilizer system.

Remote starter NO/YES No remote starter system is applied to this model.

However, must select “ ” to confirm that this vehicle
doesn’t have remote starter.

Vehicle speed signal CAN/WIRE CAN Select.

ABS or ESP NO/YES Select “ ” only for the vehicle with ABS or ESP system.

TOD/Part time TC (4WD) NO/YES Select “ ” only for the vehicle with part time TC system.

Air conditioner NO/YES Select “ ” only for the vehicle with A/C system.
(W/O Aircon : NO)
Neutral signal input NO/YES(WIRE)/CAN Select “ ” only for the vehicle with M/T neutral switch.
(M/T “N” signal)

Chassis Related Coding Item

Variant Coding Item Selection Description

Engine model D20DT/G23D Select the appropriate engine.
DOM/EXP DOM/GENERAL/EU Select the region.
Telematics Yes/No W/ Telematics: Yes
W/O Telematics: No
Selector lever MT/DC5AT/BTRA AT Select the appropriate system.
Transmission ION(BTRA)/DC LE- Select the appropriate selector lever.
VER/DURA LEVER (For DI engine equipped vehicle, select “ION (BTRA)”)
ABS/EBS NA/ABS/TCS/ESP Select the appropriate system.
SSPS NO/YES Select “ ” only for the vehicle with ECPS system.
Transfer case (4WD) NA/TOD/PT 4WD/ Select the appropriate system.
AWD/PT 4WD (W/O 4L)
Sedan/Limousine SEDAN/LIMOUSINE Select “SEDAN” - Automatic coding.
Vehicle type ACTYON Select “ACTYON” - Automatic coding.
Coding CODING COMPLETED Select the coding status.
EAS NA/ECS/EAS(2)/EAS(4) Select the appropriate system.
EPB NO/YES Select “Yes” only for the vehicle with EPB system.
- Automatic coding
TPMS NO/YES Select “ ” only for the vehicle with TPMS system.

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44 SCAN-100

4. If you need to change the variant coding, press “ ”

key to go back to “VARIANT CODING” screen. In the
screen, select “2] WRITE VARIANT CODING” and
press “ ”.

5. When the “WRITE VARIANT CODING VALUE” screen

is displayed, change the item by using arrow keys.

6. If you press “ ”, the message as shown in figure

appears. And, then “VARIANT CODING” screen is
displayed.

7. Follow the instructions on the display of Scan-100.

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 SCAN-100 45

SCAN
ECU
8. Select “READ VARIANT VALUE” to see the coding
coded value.

* Chassis variant coding should be done in the same

procedures as for Engine variant coding.

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46 SCAN-100

ECU Replace
Preceding Work: Perform the “Entering Diagnosis
Procedures”
1. Select “9] MISCELLANEOUS” and press “ ” in
“FUNCTION SELECTION” screen.

2. Select “3] ECU REPLACE” and press “ ” in

“FUNCTION SELECTION” screen.

3. Before starting ECU replace, check the ECU S/W

version of old ECU and new ECU.

4. When the “ECU REPLACE (STEP 2)” screen is

displayed followed by “ECU REPLACE (STEP 1)
screen, turn the ignition “OFF” and remove the
currently installed ECU.

NOTICE
• Do not turn off the Scan-100 at this time.
• Record the below data:
1) Vehicle identification number
2) Variant coding value
3) C2I coding value
4) Multi calibration

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 SCAN-100 47

5. Install the new ECU.

SCAN
ECU
6. If you turn the ignition switch to “ON” position and press “ ”, the message as shown in figure 1 (system
initialization) appears, and then “MULTI CALIBRATION” screen (figure 2) is displayed.

figure 1 figure 2

7. In “MULTI CALIBRATION” screen, select the relevent

model.

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48 SCAN-100

8. When you press “ ”, the processing message

as shown in figure appears.

9. If the multi calibration is completed successfully,

“ECU REPLACE (STEP 5) screen is displayed.
Backup data:
1) Multi calibration value
2) VIN value
3) Variant code value
4) Injector (C2I) value

10. In immobilizer equipped vehicle, the immobilizer

coding should be done after completed the multi
calibration.

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 SCAN-100 49

11. Press “ ” for the vehicle equipped with immobilizer system.

SCAN
12. Follow the instructions on the display of Scan-100.
- Identification of VIN number
- Immobilizer coding

ECU
#1 #2

#4 #3

#5 #6

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50 SCAN-100

#7 #8

# 10 #9

# 11 # 12

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 SCAN-100 51

13. Press “ ” to return to “MAIN MENU” screen.

SCAN
ECU

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52 SCAN-100

ECU Replace (Scan-100

Communication is not available)
If the Scan-100 communication is not available due to
ECU failure, replace the ECU as follows.
1. Replace the ECU with new one.

2. Select “3] ECU REPLACE” and press “ ” in

“FUNCTION SELECTION” screen.

3. If the versions of ECUs are not matched, program the

new ECU after replacement.

4. VIN/Variant Data/C21 Data is not read from ECU.

Press “ ” to run the multi calibration.

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 SCAN-100 53

5. Select the appropriate model in “MULTI CALIBRATION

SCAN
SELECTION” screen.
1) Vehicle with A/T: 2] Dom/Gen A/T
2) Vehicle with M/T: 4] Dom/Gen M/T

ECU
6. If the multi calibration is completed successfully,
the message screen shown in the figure is
displayed.
7. The VIN/Variant Data/C21 Data should be input
manually.

8. To enter the data, press “ESC” on the screen in

Step 5 and go back to main screen.
9. To enter the VIN, select “5] ECU IDENTIFICATION”
and press “ ”.

10. Press “ ” and enter the VIN again.

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54 SCAN-100

11. Enter the VIN into the number plate on the screen.
To change the number to the character, use the
arrow keys.

12. Select “6] INJECTOR (C2I) CORRECTIONS” and

press “ ” in “FUNCTION SELECTION” screen.
Remove the engine acoustic cover and enter the
16 digits code on each injector label for all of five
injectors. If any of digits is wrong, you should enter
full code again. Make sure that the VIN code is
correct. The nearest injector from the radiator is
number 1 and the number goes higher as it moves
away.

13. Select “8] VARIANT CODING” and press “PRESS”

in “FUNCTION SELECTION” screen. When the
“VARIANT CODING” screen is displayed, select
“2] WRITE VARIANT CODING” and press “PRESS”.
When the “WRITE VARIANT CODING” screen is
displayed, change the item by using arrow keys.

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 SCAN-100 55

Rail Pressure Reset

SCAN
Rail Pressure Reset Procedures
The engine ECU needs a specific amount of fuel according to the fuel supply lines and vehicle driving conditions.

ECU
However, if the fuel supply (pressure) is not achieved due to, for instance, defective fuel system, ECU desig-
nates the offset value to the high pressure pump to compensate it.
The fuel supply pressure varies according to the offset value and the engine output could be decreased due to
this variation. When the engine output decreases, check whether all rail pressure offset values is set to 0 in the
Rail Pressure Reset screen in SCAN-100. If the setting value is not 0, measure the fuel pressure with a tester.
If any defective is found, repair the affected components and reset the rail pressure offset value to 0.
The rail pressure reset procedures should be done after replacing any high pressure pump and fuel
system related components.

1. Select the vehicle model.

2. Select “2] RAIL PRESSURE RESET” in “FUNCTION

SELECTION” screen.

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56 SCAN-100

3. Enter the current rail pressure value and press

[ENTER] to reset the offset value.

4. The screen returns back to step 3 after displaying

the [RAIL PRESSURE RESET IS SUCCESSFUL]
message.

NOTICE
• If the offset value is not set to 0, check the fuel pres-
sure and other DTC generations before starting the
rail pressure reset operation.

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ECU
 ECU 3

SCAN
TROUBLE DIAGNOSIS TABLE

ECU
INDEX OF DTC ........................................................ 4
Trouble diagnosis table .............................................................. 7

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4 ECU

INDEX OF DTC
P0102 Low HFM Sensor Signal (Circuit Open) ...................... 7 P0118 Coolant Temperature Sensor Malfunction - Short ......... 19
P0103 High HFM Sensor Signal (Circuit Short) ...................... 7 P0117 Coolant Temperature Sensor Malfunction - Open .......... 20
P0100 Air Mass Flow (HFM) Malfunction (Vref) .................... 8 P0115 Supply Voltage Fault to Coolant Temperature Sensor ... 20
P0344 Cam Position Sensor Malfunction P0685 Main Relay Malfunction ............................................... 20
(Cam Signal Missing) ............................................... 8 P1405 EGR Solenoid Valve Malfunction - Short to ground ........ 20
P0341 Cam Position Sensor Malfunction P1406 EGR Solenoid Valve Malfunction - Short to +Batt ...... 20
(Poor Synchronization) .............................................. 8
P1480 Condenser Fan #1 Circuit Malfunction - Open ........... 21
P0219 Too Small Clearance of Crank Angle Sensor .............. 8
P1481 Condenser Fan #1 Circuit Malfunction - Short ........... 21
P0336 Too Large Clearance of Crank Angle Sensor ............. 9
P1482 Condenser Fan #1 Circuit Malfunction - Short to
P0372 Crank Angle Sensor Malfunction ................................. 9 Ground ........................................................................ 21
P1107 Barometric Sensor (Low) ............................................ 9 P1526 Condenser Fan #2 Circuit Malfunction - Open ........... 21
P1108 Barometric Sensor (High) ............................................ 9 P1527 Condenser Fan #2 Circuit Malfunction - Short ........... 21
P1105 Barometric Sensor Circuit Short (Vref) ...................... 9 P1528 Condenser Fan #2 Circuit Malfunction - Short to
P0562 Low Battery Voltage .................................................. 10 Ground ........................................................................ 21
P0563 High Battery Voltage ................................................... 10 P0325 Accelerometer #1 (Knock Sensor) Malfunction ......... 22
P0560 Battery Voltage Malfunction ....................................... 10 P0330 Accelerometer #2 (Knock Sensor) Malfunction
P0109 Low Booster Pressure Sensor Signal ....................... 11 (only D27DT) ............................................................... 22

P0106 High Booster Pressure Sensor Signal ....................... 11 P1611 Injector Bank #1 Malfunction - Low Voltage .............. 22

P0107 Booster Pressure Sensor Open/GND Short .............. 12 P1612 Injector Bank #1 Malfunction - High Voltage .............. 23

P0108 Booster Pressure Sensor Short ................................. 12 P1618 Injector Bank #2 Malfunction - Low Voltage .............. 23

P0105 Supply Voltage Fault to Booster Pressure Sensor ..... 13 P1619 Injector Bank #2 Malfunction - High Voltage .............. 23

P1106 Booster Pressure Sensor Malfunction ....................... 13 P0263 Injector #1 Balancing Fault ......................................... 24

P1109 Booster Pressure Sensor Initial Check Fault ............. 14 P0266 Injector #2 Balancing Fault ......................................... 24

P0571 Brake Pedal Switch Fault ........................................... 14 P0272 Injector #4 Balancing Fault ......................................... 24

P1572 Brake Lamp Signal Fault ............................................. 15 P0275 Injector #5 Balancing Fault (only D27DT) ................... 24

P1571 Brake Lamp Signal Fault ............................................. 15 P0269 Injector #3 Balancing Fault ......................................... 24

P1286 Low Resistance for Injector #1 wiring harness ........ 15 P0201 Injector #1 Circuit Open .............................................. 24

P1287 High Resistance for Injector #1 wiring harness ........ 16 P0202 Injector #2 Circuit Open .............................................. 24

P1288 Low Resistance for Injector #2 wiring harness ........ 16 P0204 Injector #4 Circuit Open .............................................. 25

P1289 High Resistance for Injector #2 wiring harness ........ 16 P0205 Injector #5 Circuit Open (only D27DT) ........................ 25

P1292 Low Resistance for Injector #4 wiring harness ........ 17 P0203 Injector #3 Circuit Open .............................................. 25

P1293 High Resistance for Injector #4 wiring harness ........ 17 P1201 Injector #1 Circuit Short .............................................. 25

P1294 Low Resistance for Injector #5 wiring harness P1202 Injector #2 Circuit Short .............................................. 25
(only D27DT) ............................................................... 17 P1204 Injector #4 Circuit Short .............................................. 25
P1295 High Resistance for Injector #5 wiring harness P1205 Injector #5 Circuit Short (only D27DT) ....................... 25
(only D27DT) ............................................................... 18 P1203 Injector #3 Circuit Short .............................................. 26
P1290 Low Resistance for Injector #3 wiring harness ........ 18 P0182 Fuel temperature sensor - Short to Ground .............. 26
P1291 High Resistance for Injector #3 wiring harness ........ 18 P0183 Fuel temperature sensor - Short to B+ ...................... 26
P0704 Clutch switch malfunction .......................................... 18 P0180 Fuel temperature sensor - Vref ................................. 27
P1115 Coolant Temperature Sensor Malfunction .................. 19 P1678 Glow Plug Drive Malfunction - Open .......................... 27

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 5

P1679 Glow Plug Drive Malfunction - Short .......................... 27 P0223 Accelerator Pedal Sensor #2 Malfunction - Short ...... 38

SCAN
P1680 Glow Plug Drive Malfunction - Short to Ground ......... 27 P0220 Accelerator Pedal Sensor #2 Malfunction - Supply
P1530 #1 Heater operating circuit - Open ............................ 27 Voltage Fault ............................................................... 38

P1531 #1 Heater operating circuit - Short to B+ ................... 28 P0192 Fuel Rail Pressure Sensor Malfunction - Open .......... 39

ECU
P1532 #1 Heater operating circuit - Short to Ground ........... 28 P0193 Fuel Rail Pressure Sensor Malfunction - Short .......... 39

P1534 #2 Heater operating circuit - Open ............................ 28 P0190 Supply Voltage Fault to Fuel Rail Pressure Sensor ........ 39

P1535 #2 Heater operating circuit - Short to B+ ................... 28 P0191 Fuel Rail Pressure Sensor Signal Fault ...................... 40

P1536 #2 Heater operating circuit - Short to Ground ........... 28 P1192 Fuel Rail Pressure Sensor Initial Signal Fault - Low ......... 40

P1254 Maximum Rail Pressure Control Malfunction P1193 Fuel Rail Pressure Sensor Initial Signal Fault - High ......... 40
(IMV Fault) .................................................................. 29 P1190 Fuel Rail Pressure Sensor Initial Signal Fault ............. 41
P1253 Minimum Rail Pressure Control Malfunction P0215 Main Relay Fault - Stuck ............................................. 41
(IMV Fault) .................................................................. 29 P1500 Vehicle Speed Fault .................................................... 41
P1256 Too Small Transfer Pressure Fuel in Rail Pressure P0642 ECU Supply Voltage 1 Fault - Low (5 V) .................... 41
System ........................................................................ 30
P0643 ECU Supply Voltage 1 Fault - High (5 V) .................... 42
P1257 Too Large Transfer Pressure Fuel in Rail Pressure
P0641 ECU Supply Voltage 1 Fault (5 V) .............................. 42
System ........................................................................ 30
P0652 ECU Supply Voltage 2 Fault - Low (5 V) .................... 42
P1258 Too Small High Pressure Fuel in Rail Pressure
P0653 ECU Supply Voltage 2 Fault - High (5 V) .................... 42
System ........................................................................ 31
P0651 ECU Supply Voltage 2 Fault (5 V) .............................. 42
P1259 Too Large High Pressure Fuel in Rail Pressure
System ...................................................................... 31 P0698 ECU Supply Voltage Fault - Low (2.5 V) .................... 43

P1191 Pressure Build Up - Too Slow .................................... 32 P0699 ECU Supply Voltage Fault - High (2.5 V) .................... 43

P0255 IMV Driver Circuit Malfunction - Open ........................ 32 P0697 ECU Supply Voltage Fault (2.5 V) .............................. 43

P0251 IMV Driver Circuit Malfunction - Short ........................ 32 P0245 Turbo Charger Actuator Circuit Fault - Short ............. 43

P0253 IMV Driver Circuit Malfunction - Short to Ground ...... 32 P0246 Turbo Charger Actuator Circuit Fault - Short to B+ ....... 43

P0112 Intake Air Temperature Circuit Malfunction - Open ........ 34 P0606 ECU Watchdog Fault ................................................... 43

P0110 Intake Air Temperature Circuit Malfunction - Source P1607 ECU Injector Cut Fault ................................................. 43
Power Problem ........................................................... 35 P1600 ECU Shut Down Fault ................................................. 44
P1171 #1 Injector MDP Malfunction ....................................... 35 P1601 ECU Fault .................................................................... 44
P1172 #2 Injector MDP Malfunction ....................................... 35 P1602 ECU Fault .................................................................... 44
P1174 #4 Injector MDP Malfunction ....................................... 36 P1614 ECU C2I/MDP Fault ...................................................... 44
P1175 #5 Injector MDP Malfunction (only D27DT) ................. 36 P1615 ECU Fault .................................................................... 44
P1173 #3 Injector MDP Malfunction ....................................... 36 P1616 ECU Fault .................................................................... 44
P1252 Too High IMV Pressure ............................................... 36 P1606 ECU Fault .................................................................... 44
P1120 Accelerator Pedal Sensor #1 Malfunction ................. 36 P1620 ECU Fault .................................................................... 44
P1121 Accelerator Pedal Sensor #2 Malfunction ................. 37 P1621 ECU Fault .................................................................... 44
P1122 Accelerator Pedal Sensor Malfunction P1622 ECU Fault .................................................................... 44
(Limp Home Mode) ...................................................... 37
P1148 Accelerometer (Knock Sensor) Learning Fault ......... 45
P1123 Accelerator Pedal Sensor Malfunction
P0400 EGR Control Valve Fault ............................................. 45
(Reducde Torque Mode) ......................................... 37
P1235 VGT Operation Fault ................................................... 45
P1124 Accelerator Pedal Sensor Malfunction - Stuck .... 37
P1608 ECU Fault .................................................................... 45
P0122 Accelerator Pedal Sensor #1 Malfunction - Open ....... 37
P0335 No Crank Signals ........................................................ 45
P0123 Accelerator Pedal Sensor #1 Malfunction - Short ...... 37
P1170 Torque Trim Fault - High .............................................. 45
P0120 Accelerator Pedal Sensor #1 Malfunction - Supply
P1676 Glow Plug Communication Fault ................................. 46
Voltage Fault ............................................................... 38
P1677 Glow Plug Controller Fault .......................................... 46
P0222 Accelerator Pedal Sensor #2 Malfunction - Open ....... 38

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
6 ECU

P0671 #3 Glow Plug Fault - Open ......................................... 46 P1633 Immobilizer Fault (refer to immobilizer section) .......... 49
P0672 #4 Glow Plug Fault - Open ......................................... 46 P0633 Immobilizer Fault (refer to immobilizer section) .......... 49
P0673 #5 Glow Plug Fault - Open (only D27DT) ................... 46 P1636 Immobilizer Fault (refer to immobilizer section) .......... 50
P0674 #1 Glow Plug Fault - Open ......................................... 47 P1102 High HFM Sensor Signal ............................................. 50
P0675 #2 Glow Plug Fault - Open ......................................... 47 P1103 Low HFM Sensor Signal ............................................. 50
P1671 #3 Glow Plug Fault - Short (B+) ................................. 47 P1501 Variant coding failure (vehicle speed) ....................... 50
P1672 #4 Glow Plug Fault - Short (B+) ................................. 47 P1503 Vehicle speed sensor input failure ............................ 50
P1673 #5 Glow Plug Fault - Short (B+) (only D27DT) ........... 47 P0600 CAN BUS failure .......................................................... 50
P1674 #1 Glow Plug Fault - Short (B+) ................................. 47 P0602 Vehicle speed sensor coding failure ......................... 50
P1675 #2 Glow Plug Fault - Short (B+) ................................. 48 P0608 ABS/ESP coding failure .............................................. 50
P0700 TCU Signal Fault .......................................................... 48 P0613 TCU coding failure ...................................................... 50
P1540 Air Conditioner Operating Circuit Fault - Open ........... 48 P0644 CAN cluster failure ..................................................... 50
P1541 Air Conditioner Operating Circuit Fault - Short .......... 48 P1565 Auto cruise switch failure (Acceleration) ................. 51
P1542 Air Conditioner Operating Circuit Fault - Short to P1566 Auto cruise switch failure (OFF) ............................... 51
Ground ...................................................................... 48 P1567 Auto cruise switch failure .......................................... 51
P1149 Too High Water Level in Fuel Filter ............................. 48 P1568 Auto cruise switch failure (Deceleration) ................. 51
P1634 Immobilizer Fault (refer to immobilizer section) .......... 48 P1569 Auto cruise switch failure (Safety) ........................... 51
P1635 No response from Immobilizer P3040 ECU internal failure ..................................................... 51
(refer to immobilizer section) ..................................... 48
P3041 ECU internal failure (only D27DT) ............................... 51
P1630 Wrong response from Immobilizer
P1657 Engine mount control failure (Open) .......................... 51
(refer to immobilizer section) ..................................... 49
P1658 Engine mount control failure (Short to B+) ................. 51
P1631 Immobilizer Fault (refer to immobilizer section) .......... 49
P1659 Engine mount control failure (Short to ground) .......... 51
P1632 Immobilizer Fault (refer to immobilizer section) .......... 49
P0805 Abnormal neutral signal .............................................. 51

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 7

TROUBLE DIAGNOSIS TABLE

SCAN
Torque Torque Delayed Immediately Limp
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode

ECU
P0102 Low HFM Sensor Signal - HFM sensing values are lower than
(Circuit Open) minimum sensing values.
- Check the resistance in HFM sensor.
- Check the ECU wiring harness (open
and poor contact).
• Check the ECU pin #83 and #84
for open circuit.
- Actual air mass flow vs. Output
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
- Replace the ECU if required.
P0103 High HFM Sensor Signal - HFM sensing values are higher than
(Circuit Short) maximum sensing values.
- Check the resistance in HFM sensor.
- Check the ECU wiring harness (open
and poor contact).
• Check the ECU pin #83 and #84
for open circuit.
- Actual air mass flow vs. Output
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
8 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0100 Air Mass Flow (HFM) Mal- - The external power supply is faulty.
function (Vref) • Check the external power supply.
• Check the sensor wiring harness
(open, short, poor contact).
- Actual air mass flow vs. Output
voltages.
• -20 Kg/h: 0.47 V
• 0 Kg/h: 0.99 V
• 10 Kg/h: 1.2226 ~ 1.2398 V
• 15 Kg/h: 1.3552 ~ 1.3778 V
• 30 Kg/h: 1.6783 ~ 1.7146 V
• 60 Kg/h: 2.1619 ~ 2.2057 V
• 120 Kg/h: 2.7215 ~ 2.7762 V
• 250 Kg/h: 3.4388 ~ 3.5037 V
• 370 Kg/h: 3.8796 ~ 3.9511 V
• 480 Kg/h: 4.1945 ~ 4.2683 V
• 640 Kg/h: 4.5667 ~ 4.6469 V
- Replace the ECU if required.
P0344 Cam Position Sensor Mal- - No cam recognition signal (missing O
function (Cam Signal Missing) events).
- Check the source voltage of cam po-
sition sensor (ECU pin #111)
(specified value: 4.5 ~ 12 V).
- Check the sensor wiring harness for
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
- Measure the air gap: 0.2 ~ 1.8 mm
- Replace the ECU if required.
P0341 Cam Position Sensor Malfunc- - Not synchronized with Crank angle O
tion (Poor Synchronization) signal.
- Check the source voltage of cam posi-
tion sensor (specified value: 4.5 ~ 12 V).
- Check the sensor wiring harness for
ECU pin #103 and #104 (open, short,
poor contact).
- Check the cam position sensor.
- Measure the air gap: 0.2 ~ 1.8 mm
- Replace the ECU if required.
P0219 Too Small Clearance of - Crank angle signal faults or clearance O
Crank Angle Sensor too close.
- Check the sensor wiring harness for
ECU pin #90 and #82 (open, short,
poor contact).
- Check the resistance of crank angle
sensor: 1090 Ω ± 15 %.
- Measure the air gap: 0.3 ~ 1.3 mm
• 1.3 mm of air gap: outputs 1.0 V at
40 rpm
• 0.3 mm of air gap: outputs 150 V
at 7000 rpm
- Check the teeth condition.
• Drive plate (A/T), DMF (M/T)
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 9

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0336 Too Large Clearance of - Air gap of crank angle sensor is O
Crank Angle Sensor abnormal.
- Check the sensor wiring harness for

ECU
ECU pin #90 and #82 (open, short,
poor contact).
- Check the resistance of crank angle
sensor: 1090 Ω ± 15 %.
- Measure the air gap: 0.3 ~ 1.3 mm
• 1.3 mm of air gap: outputs 1.0 V at
40 rpm
• 0.3 mm of air gap: outputs 150 V
at 7000 rpm
- Check the teeth condition.
• Drive plate (A/T), DMF (M/T)
- Replace the ECU if required.
P0372 Crank Angle Sensor Mal- - Even though cam position recognition O
function is normal, no crank angle signal rec-
ognition (missing tooth).
- Check the sensor wiring harness for
ECU pin #90 and #82 (open, short,
poor contact).
- Check the resistance of crank angle
sensor: 1090 Ω ± 15 %.
- Measure the air gap: 0.3 ~ 1.3 mm
• 1.3 mm of air gap: outputs 1.0 V at
40 rpm
• 0.3 mm of air gap: outputs 150 V
at 7000 rpm
- Check the teeth condition.
• Drive plate (A/T), DMF (M/T)
- Replace the ECU if required.
P1107 Barometric Sensor (Low) - Out of range about barometric sen-
sor (short to ground).
- Actual barometric pressure vs. Out-
put voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.
P1108 Barometric Sensor (High) - Out of range about barometric sen-
sor (short to B+).
- Actual barometric pressure vs. Out-
put voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.
P1105 Barometric Sensor Circuit - Out of range about barometric sen-
Short (Vref) sor (over voltage).
- Actual barometric pressure vs. Out-
put voltages.
• 15 Kpa: 0 V 35 Kpa: 1.0 V
• 55 Kpa: 2.0 V 80 Kpa: 3.0 V
• 100 Kpa: 4.0 V 110 Kpa: 4.5 V
- Replace the ECU.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
10 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0562 Low Battery Voltage - Malfunction in recognition of system O
source voltage (Lower than threshold).
• Less than minimum 8 Volts in 2000
rpm below
• Less than 10 Volts in 2000 rpm above.
- Check the battery wiring harness for
ECU pin #3, #4 and #5 (open, short,
poor contact).
- Check the battery main relay and fuse.
- Check the body ground.
- Measure the resistance between
body ground and ECU ground.
• Repair the ECU ground if the re-
sistance is high.
- Replace the ECU if required.
P0563 High Battery Voltage - Malfunction in recognition of system O
source voltage (Higher than threshold).
• More than minimum 16 Volts in
2000 rpm below
- Check the battery wiring harness for
ECU pin #3, #4 and #5 (open, short,
poor contact).
- Check the alternator.
- Check the body ground.
- Measure the resistance between
body ground and ECU ground.
• Repair the ECU ground if the re-
sistance is high.
- Replace the ECU if required.
P0560 Battery Voltage Malfunc- - Malfunction in recognition of system O
tion source voltage (A/D converter faults).
• Less than minimum 8 Volts in 2000
rpm below
• Less than 10 Volts in 2000 rpm above.
- Check the battery wiring harness for
ECU pin #3, #4 and #5 (open, short,
poor contact).
- Check the battery main relay and fuse.
- Check the body ground.
- Measure the resistance between
body ground and ECU ground.
• Repair the ECU ground if the re-
sistance is high.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 11

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0109 Low Booster Pressure - Out of signal range about boost pres-
Sensor Signal sure sensor at Ignition key-On and En-
gine Stop (Lower than specified values).

ECU
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output
voltages.
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for ECU
pin #99 and #100 (open, poor contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction
P0106 High Booster Pressure - Out of signal range about boost pres-
Sensor Signal sure sensor at Ignition key-On and
Engine Stop (Higher than specified
values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output
voltages.
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
12 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0107 Booster Pressure Sensor - Out of signal range about boost pres-
Open/GND Short sure sensor at Engine running condi-
tion (Lower than specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output volt-
ages
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction
P0108 Booster Pressure Sensor - Out of signal range about boost pres-
Short sure sensor at Engine running condi-
tion (Higher than specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output volt-
ages
• Raw Signal Range: 0.545~2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 13

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0105 Supply Voltage Fault to - Out of range of supply voltages about
Booster Pressure Sensor boost pressure sensor at Ignition key-
On and Engine Stop (Higher than

ECU
specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output voltages
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #100 and #108 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction
P1106 Booster Pressure Sensor - Out of range of supply voltages about
Malfunction boost pressure sensor at Ignition key-
On and Engine Stop (Higher than
specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output voltages.
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
14 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1109 Booster Pressure Sensor - Implausible signal values or range
Initial Check Fault about boost pressure sensor at En-
gine running condition (Higher than
specified values).
- Check the supply voltage to sensor.
- Actual boost pressure vs. Output volt-
ages
• Raw Signal Range: 0.545 ~ 2.490 bar
• 0.4 bar: 0.6120 V
• 1.4 bar: 2.6520 V
• 2.4 bar: 4.6920 V
- Check the sensor wiring harness for
ECU pin #99 and #100 (open, poor
contact).
- Visually check sensor and replace if
required.
- Replace the ECU if required.
- Check whether existing or not about
turbo boosting control malfunction
(P1235) simultaneously.
- If there is turbo boost control fault,
Should be checked followings also;
• Leakage before turbo system
• Vacuum pump malfunction
• Waste gate’ solenoid valve
• Turbo charger system defect or
malfunction itself
• Air inlet restriction
• Exhaust system restriction
P0571 Brake Pedal Switch Fault - The brake pedal switch or light switch
is faulty.
• Brake pedal switch: Normal Close
(NC)
• Light switch: Normal Open (NO)
• When operating the brake switch,
one signal (NO) is sent to auto
cruise and the other (NC) is sent
to brake lamp.
- Check the brake and light switch wir-
ing harness.
- Check the supply voltage to brake and
light switch (12 V).
- Check the brake and light switch for
contact.
- Check the ECU wiring harness for ECU
pin #77 and #58 (short, poor contact).
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 15

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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1572 Brake Lamp Signal Fault - The brake pedal switch or light switch
is faulty.
• Brake pedal switch: Normal Close

ECU
(NC)
• Light switch: Normal Open (NO)
• When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal and light
switch wiring harness.
- Check the supply voltage to brake
pedal and light switch (12 V).
- Check the brake pedal and light
switch for contact.
- Check the ECU wiring harness for ECU
pin #58 (open, short, poor contact).
- Replace the ECU if required.
P1571 Brake Lamp Signal Fault - The brake pedal switch is faulty.
• Brake pedal switch: Normal Close
(NC)
• Light switch: Normal Open (NO)
• When operating the brake pedal
switch, one signal (NO) is sent to
auto cruise and the other (NC) is
sent to brake lamp.
- Check the brake pedal switch wiring
harness.
- Check the supply voltage to brake
pedal switch (12 V).
- Check the brake pedal switch for
contact.
- Check the ECU wiring harness for ECU
pin #77 (open, short, poor contact).
- Replace the ECU if required.
P1286 Low Resistance for Injec- - Out of range about wiring harness
tor #1 wiring harness resistance for Injector #1.
• Low: Less than 0.115 Ω (injector
circuit open)
- Check the injector #1 wiring harness
and electric isolation.
- Check the injector #1 wiring harness
for open circuit.
• If the pin in injector #1 is defective,
replace injector #1 and perform
C2I coding, then check again.
• If the pin in injector #1 is not
defective, check the ECU wiring
harness.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
16 ECU

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1287 High Resistance for Injec- - Out of range about wiring harness
tor #1 wiring harness resistance for Injector #1.
• High: More than 0.728 Ω (injector
circuit short)
- Check the injector #1 wiring harness
and electric isolation.
- Check the injector #1 wiring harness
for short circuit.
• If the trouble still exists after re-
moving the injector connector, re-
place injector #1 and perform C2I
coding, then check again.
• If the trouble is fixed after remov-
ing the injector connector, check
the wiring harness between ECU
and injector.
- Replace the ECU if required.
P1288 Low Resistance for Injec- - Out of range about wiring harness
tor #2 wiring harness resistance for Injector #2.
• Low: Less than 0.115 Ω (injector
circuit open)
- Check the injector #2 wiring harness
and electric isolation.
- Check the injector #2 wiring harness
for open circuit.
• If the pin in injector #2 is defective,
replace injector #2 and perform
C2I coding, then check again.
• If the pin in injector #2 is not
defective, check the ECU wiring
harness.
- Replace the ECU if required.
P1289 High Resistance for Injec- - Out of range about wiring harness
tor #2 wiring harness resistance for Injector #2.
• High: More than 0.728 Ω (injector
circuit short)
- Check the injector #2 wiring harness
and electric isolation.
- Check the injector #2 wiring harness
for short circuit.
• If the trouble still exists after re-
moving the injector connector, re-
place injector #2 and perform C2I
coding, then check again.
• If the trouble is fixed after remov-
ing the injector connector, check
the wiring harness between ECU
and injector.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 17

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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1292 Low Resistance for Injec- - Out of range about wiring harness
tor #4 wiring harness resistance for Injector #4.
• Low: Less than 0.115 Ω (injector

ECU
circuit open)
- Check the injector #4 wiring harness
and electric isolation.
- Check the injector #4 wiring harness
for open circuit.
• If the pin in injector #4 is defective,
replace injector #4 and perform
C2I coding, then check again.
• If the pin in injector #4 is not
defective, check the ECU wiring
harness.
- Replace the ECU if required.
P1293 High Resistance for Injec- - Out of range about wiring harness
tor #4 wiring harness resistance for Injector #4.
• High: More than 0.728 Ω (injector
circuit short)
- Check the injector #4 wiring harness
and electric isolation.
- Check the injector #4 wiring harness
for short circuit.
• If the trouble still exists after re-
moving the injector connector, re-
place injector #4 and perform C2I
coding, then check again.
• If the trouble is fixed after remov-
ing the injector connector, check
the wiring harness between ECU
and injector.
- Replace the ECU if required.
P1294 Low Resistance for Injec- - Out of range about wiring harness
tor #5 wiring harness resistance for Injector #5.
(only D27DT) • Low: Less than 0.115 Ω (injector
circuit open)
- Check the injector #5 wiring harness
and electric isolation.
- Check the injector #5 wiring harness
for open circuit.
• If the pin in injector #5 is defective,
replace injector #5 and perform
C2I coding, then check again.
• If the pin in injector #5 is not
defective, check the ECU wiring
harness.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1295 High Resistance for Injec- - Out of range about wiring harness
tor #5 wiring harness resistance for Injector #5.
(only D27DT) • High: More than 0.728 Ω (injector
circuit short)
- Check the injector #5 wiring harness
and electric isolation.
- Check the injector #5 wiring harness
for short circuit.
• If the trouble still exists after re-
moving the injector connector, re-
place injector #5 and perform C2I
coding, then check again.
• If the trouble is fixed after remov-
ing the injector connector, check
the wiring harness between ECU
and injector.
- Replace the ECU if required.
P1290 Low Resistance for Injec- - Out of range about wiring harness
tor #3 wiring harness resistance for Injector #3.
• Low: Less than 0.115 Ω (injector
circuit open)
- Check the injector #3 wiring harness
and electric isolation.
- Check the injector #3 wiring harness
for open circuit.
• If the pin in injector #3 is defective,
replace injector #3 and perform
C2I coding, then check again.
• If the pin in injector #3 is not
defective, check the ECU wiring
harness.
- Replace the ECU if required.
P1291 High Resistance for Injec- - Out of range about wiring harness
tor #3 wiring harness resistance for Injector #3.
• High: More than 0.728 Ω (injector
circuit short)
- Check the injector #3 wiring harness
and electric isolation.
- Check the injector #3 wiring harness
for short circuit.
• If the trouble still exists after re-
moving the injector connector, re-
place injector #3 and perform C2I
coding, then check again.
• If the trouble is fixed after remov-
ing the injector connector, check
the wiring harness between ECU
and injector.
- Replace the ECU if required.
P0704 Clutch switch malfunction - The clutch switch is faulty (Manual
Transmission Only).
- Check the switch wiring harness.
• Check the ECU pin #38 for open,
short and poor contact.
- Check the switch supply voltage and
operations.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1115 Coolant Temperature Sen- - Implausible values of coolant tem-
sor Malfunction perature (If the temperature is below
the limits values after warm up).

ECU
- If Fuel temperature is invalid, the pre-
vious coolant temperature is retained.
- Check the supply voltage to sensor.
- Actual coolant temp. vs. Resistance
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (open,
short and poor contact).
• ECU pin #101 and #102
- Visually check the sensor and re-
place if required.
- Check the thermostat, water pump ra-
diator related coolant route
(thermostat stuck).
- Replace the ECU if required.
P0118 Coolant Temperature Sen- - Malfunction in recognition of coolant
sor Malfunction - Short temperature
• More than maximum values (Circuit
Short)
• External power supply malfunction
- If Fuel temperature is invalid, the pre-
vious coolant temperature is retained.
- Check the supply voltage to sensor.
- Actual coolant temp. vs. Resistance
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (short and
poor contact).
• ECU pin #101 and #102
- Visually check the sensor and re-
place if required.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0117 Coolant Temperature Sen- - Malfunction in recognition of coolant
sor Malfunction - Open temperature
• Less than minimum values (Circuit
Open)
• External power supply malfunction
- If Fuel temperature is invalid, the pre-
vious coolant temperature is retained.
- Check the supply voltage to sensor.
- Actual coolant temp. vs. Resistance
• 20°C: 2449 Ω
• 50°C: 826.3 Ω
• 80°C: 321.4 Ω
• 100°C: 112.9 Ω
- Check the wiring harness (open and
poor contact).
• ECU pin #101 and #102
- Visually check the sensor and re-
place if required.
- Replace the ECU if required.
P0115 Supply Voltage Fault to - Check if the supply voltage of approx.
Coolant Temperature Sen- 12 V is applied.
sor
P0685 Main Relay Malfunction - The the main relay is unexpectedly
high/low state (ECU is supplied after
3 seconds).
- Relay resistance: 92 ± 9 Ω (at 20°C)
- Check the relay wiring harness (open,
short and poor contact).
• Check for open and short: ECU pin #9.
- If the forced operation is not available,
replace the ECU.
P1405 EGR Solenoid Valve - Out of range about EGR gas: High.
Malfunction - Short to • EGR controller circuit: Open or
ground short to ground
- Check the EGR actuator wiring harness.
- Check the supply voltage to EGR so-
lenoid valve.
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR
actuator: 15.4 Ω.
- Check the ECU wiring harness for
open and short.
• ECU pin #96
P1406 EGR Solenoid Valve - Out of range about EGR gas: Low.
Malfunction - Short to • EGR controller circuit: Short to battery
+Batt
- Check the EGR actuator wiring harness.
- Check the supply voltage to EGR so-
lenoid valve.
- Check the EGR solenoid valve.
- Check the EGR valve for stick.
- Check the resistance of EGR
actuator: 15.4 Ω
- Check the ECU wiring harness for
open and short.
• ECU pin #96

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1480 Condenser Fan #1 Circuit - Condenser fan #1: Open
Malfunction - Open - Check the relay and relay wiring
harness.

ECU
- Check the ECU wiring harness for
open and short.
• ECU pin #80
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.
P1481 Condenser Fan #1 Circuit - Condenser fan #1: Short
Malfunction - Short - Check the relay and relay wiring
harness.
- Check the ECU wiring harness for
open and short.
• ECU pin #80
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.
P1482 Condenser Fan #1 Circuit - Condenser fan #1: Short to ground.
Malfunction - Short to Ground - Check the relay and relay wiring
harness.
- Check the ECU wiring harness for
open and short.
• ECU pin #80
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.
P1526 Condenser Fan #2 Circuit - Condenser fan #2: Open
Malfunction - Open - Check the relay and relay wiring
harness.
- Check the ECU wiring harness for
open and short.
• ECU pin #81
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.
P1527 Condenser Fan #2 Circuit - Condenser fan #2: Short
Malfunction - Short - Check the relay and relay wiring
harness.
- Check the ECU wiring harness for
open and short.
• ECU pin #81
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.
P1528 Condenser Fan #2 Circuit - Condenser fan #2: Short to ground
Malfunction - Short to Ground - Check the relay and relay wiring
harness.
- Check the ECU wiring harness for
open and short.
• ECU pin #81
- If the forced operation is not avail-
able after replacing the relay, replace
the ECU.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
22 ECU

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0325 Accelerometer #1 (Knock - The signal / noise ratio is too low about
Sensor) Malfunction accelerometer # 1.
- Check the accelerometer wiring har-
ness and tightening torque.
• Tightening torque: 20 ± 5 Nm
- Check the ECU wiring harness for
open and short.
• ECU pin #45 and #46
- If the trouble still exists even after
replacing the accelerometer, replace
the ECU.
P0330 Accelerometer #2 (Knock - The signal / noise ratio is too low about
Sensor) Malfunction accelerometer # 2.
(only D27DT) - Check the accelerometer wiring har-
ness and tightening torque.
• Tightening torque: 20 ± 5 Nm
- Check the ECU wiring harness for
open and short.
• ECU pin #44 and #63
- If the trouble still exists even after
replacing the accelerometer, replace
the ECU.
P1611 Injector Bank #1 Malfunc- - Malfunction of injector (#1, #4, #3)
tion - Low Voltage circuit (Low): Short to Ground or to
Battery.
- Operating voltage: 6 ~ 18 V
- Check the injector bank #1: Open and
poor contact
- Check if the trouble recurs with the
injectors removed and the ignition key
“OFF”.
• If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while in-
stalling the injectors one by one with
the ignition key “ON”.
• If recurred, replace the injector
(perform C2I coding after replacement).
• Check the other injectors with
same manner.
- Check the ECU wiring harness.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 23

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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1612 Injector Bank #1 Malfunc- - Malfunction of injector (#1, #4, #3) cir- O
tion - High Voltage cuit (High): Short to Ground or to Battery.
- Operating voltage: 6 ~ 18 V

ECU
- Check the injector bank #1: Short and
poor contact
- Check if the trouble recurs with the injec-
tors removed and the ignition key “OFF”.
• If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while in-
stalling the injectors one by one with
the ignition key “ON”.
• If recurred, replace the injector
(perform C2I coding after replacement).
• Check the other injectors with
same manner.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1618 Injector Bank #2 Malfunc- - Malfunction of injector (#2, #5) circuit
tion - Low Voltage (Low): Short to Ground or to Battery.
- Operating voltage: 6 ~ 18 V
- Check the injector bank #2: Open and
poor contact
- Check if the trouble recurs with the injec-
tors removed and the ignition key “OFF”.
• If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while in-
stalling the injectors one by one with
the ignition key “ON”.
• If recurred, replace the injector
(perform C2I coding after replacement).
• Check the other injectors with
same manner.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1619 Injector Bank #2 Malfunc- - Malfunction of injector (#2, #5) circuit O
tion - High Voltage (High): Short to Ground or to Battery.
- Operating voltage: 6 ~ 18 V
- Check the injector bank #2: Short and
poor contact
- Check if the trouble recurs with the injec-
tors removed and the ignition key “OFF”.
• If recurred, check the injector and
ECU wiring harness.
- Check if the trouble recurs while in-
stalling the injectors one by one with
the ignition key “ON”.
• If recurred, replace the injector
(perform C2I coding after replacement).
• Check the other injectors with
same manner.
- Check the ECU wiring harness.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0263 Injector #1 Balancing Fault - Injector #1 cylinder balancing faults
(Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
C2I coding after replacement).
P0266 Injector #2 Balancing Fault - Injector #2 cylinder balancing faults
(Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
C2I coding after replacement).
P0272 Injector #4 Balancing Fault - Injector #4 cylinder balancing faults
(Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
C2I coding after replacement).
P0275 Injector #5 Balancing Fault - Injector #5 cylinder balancing faults
(only D27DT) (Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
C2I coding after replacement).
P0269 Injector #3 Balancing Fault - Injector #3 cylinder balancing faults
(Injector stuck closed).
- Check the injector circuit for open.
- Check the glow plug.
- Check the inlet tube for clogging.
- Check the EGR.
- Replace the ECU if required (perform
C2I coding after replacement).
P0201 Injector #1 Circuit Open - Injector #1 circuit malfunction: Open. O
• If the injector pin is defective, per-
form C2I coding and check again.
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#117, #114).
- Replace the ECU if required.
P0202 Injector #2 Circuit Open - Injector #2 circuit malfunction: Open. O
• If the injector pin is defective, per-
form C2I coding and check again.
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#118, #121).
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0204 Injector #4 Circuit Open - Injector #4 circuit malfunction: Open. O
• If the injector pin is defective, per-
form C2I coding and check again.

ECU
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#117, #115).
- Replace the ECU if required.
P0205 Injector #5 Circuit Open - Injector #5 circuit malfunction: Open. O
(only D27DT) • If the injector pin is defective, per-
form C2I coding and check again.
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#118, #120).
- Replace the ECU if required.
P0203 Injector #3 Circuit Open - Injector #3 circuit malfunction: Open. O
• If the injector pin is defective, per-
form C2I coding and check again.
• If the injector pin is normal, check
the ECU wiring harness (ECU pin:
#117, #116).
- Replace the ECU if required.
P1201 Injector #1 Circuit Short - Injector #1 circuit malfunction: Short.
• If the trouble recurs with the in-
jector removed, replace the
injector. Perform C2I coding and
check again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #117, #114).
- Replace the ECU if required.
P1202 Injector #2 Circuit Short - Injector #2 circuit malfunction: Short.
• If the trouble recurs with the in-
jector removed, replace the
injector. Perform C2I coding and
check again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #118, #121).
- Replace the ECU if required.
P1204 Injector #4 Circuit Short - Injector #4 circuit malfunction: Short.
• If the trouble recurs with the in-
jector removed, replace the
injector. Perform C2I coding and
check again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #117, #115).
- Replace the ECU if required.
P1205 Injector #5 Circuit Short - Injector #5 circuit malfunction: Short.
(only D27DT) • If the trouble recurs with the in-
jector removed, replace the
injector. Perform C2I coding and
check again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #118, #120).
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
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AFFECTED VIN
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1203 Injector #3 Circuit Short - Injector #3 circuit malfunction: Short.
• If the trouble recurs with the in-
jector removed, replace the
injector. Perform C2I coding and
check again.
• If the trouble does not recur, check
the wiring harness between the in-
jector and ECU (ECU pin: #117, #116).
- Replace the ECU if required.
P0182 Fuel temperature sensor - The sensing values are higher than
- Short to Ground specified values for fuel temperature
sensor. (More than maximum sens-
ing values 140°C - Circuit Short)
- Actual fuel temp. vs. Resistance
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
- Recovery values when fuel tempera-
ture sensor failure: 95°C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
• ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P0183 Fuel temperature sensor - The sensing values are lower than
- Short to B+ specified values for fuel temperature
sensor. (Less than maximum sens-
ing values - 40°C - Circuit Open)
- Actual fuel temp. vs. Resistance
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
- Recovery values when fuel tempera-
ture sensor failure: 95°C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
• ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 27

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0180 Fuel temperature sensor - The power source circuit is faulty for
- Vref fuel temperature sensor. (Fuel tem-
perature sensor is mounted in high

ECU
pressure pump)
- Actual fuel temp. vs. Resistance
• -40°C: 75.780 Ω -20°C: 21.873 Ω
• -10°C: 12.462 Ω 0°C: 7.355 Ω
• 10°C: 4.481 Ω 20°C: 2.812 Ω
• 25°C: 2.252 Ω 30°C: 1.814 Ω
• 40°C: 1.199 Ω 50°C: 0.811 Ω
• 70°C: 0.394 Ω 90°C: 0.206 Ω
• 120°C: 0.087 Ω
- Recovery values when fuel tempera-
ture sensor failure: 95°C
- Check the supply voltage to sensor.
- Check the wiring harness for open,
short and poor contact.
• ECU pin: #109, #110
- Check the ECU wiring and replace the
ECU if required.
P1678 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Open.
tion - Open - Check the glow plug wiring harness
for open.
• ECU pin #113
- Check the glow plug relay operations.
- Check the glow plug power supply.
- Check the ECU wiring and replace the
ECU if required.
P1679 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Short.
tion - Short - Check the glow plug wiring harness
for open.
• ECU pin #113
- Check the glow plug relay operations.
- Check the glow plug power supply.
- Check the ECU wiring and replace the
ECU if required.
P1680 Glow Plug Drive Malfunc- - Glow plug circuit malfunction: Short
tion - Short to Ground to ground.
- Check the glow plug wiring harness
for open.
• ECU pin #113
- Check the glow plug relay operations.
- Check the glow plug power supply.
- Check the ECU wiring and replace the
ECU if required.
P1530 #1 Heater operating cir- - #1 heater circuit malfunction: Open.
cuit - Open - Check the wiring harness for open.
• ECU pin #61
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
28 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1531 #1 Heater operating cir- - #1 heater circuit malfunction: Short.
cuit - Short to B+ - Check the wiring harness for short.
• ECU pin #61
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.
P1532 #1 Heater operating cir- - #1 heater circuit malfunction: Short
cuit - Short to Ground to ground.
- Check the wiring harness for short.
• ECU pin #61
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.
P1534 #2 Heater operating cir- - #2 heater circuit malfunction: Open.
cuit - Open - Check the wiring harness for open.
• ECU pin #62
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.
P1535 #2 Heater operating cir- - #2 heater circuit malfunction: Short.
cuit - Short to B+ - Check the wiring harness for short.
• ECU pin #62
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.
P1536 #2 Heater operating cir- - #2 heater circuit malfunction: Short
cuit - Short to Ground to ground.
- Check the wiring harness for short.
• ECU pin #62
- Check the heater relay operations.
- If the forced operation is not available,
replace the ECU.
- Check the ECU wiring and replace the
ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 29

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1254 Maximum Rail Pressure - Rail pressure faults: Too high
Control Malfunction (IMV - Check the IMV wiring harness.
Fault)
- Check the ECU wiring harness.

ECU
• Check the ECU pin #87 for open
and short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel
pressure lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P1253 Minimum Rail Pressure - Rail pressure faults: Too low O
Control Malfunction (IMV - Check the IMV wiring harness.
Fault)
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the high pressure fuel lines, fuel
rails and high pressure pipes for leaks.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel
pressure lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
30 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1256 Too Small Transfer Pres- - Rail pressure fault: IMV current trim
sure Fuel in Rail Pressure too high, drift.
System - Check the IMV wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel
pressure lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P1257 Too Large Transfer Pres- - Rail pressure fault: IMV current trim O
sure Fuel in Rail Pressure too high, drift.
System - Check the IMV wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel
pressure lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 31

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1258 Too Small High Pressure - Rail pressure fault: IMV current trim
Fuel in Rail Pressure Sys- too high, drift.
tem - Check the IMV wiring harness.

ECU
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P1259 Too Large High Pressure - Rail pressure fault: IMV current trim
Fuel in Rail Pressure Sys- too high, drift.
tem - Check the IMV wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
32 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1191 Pressure Build Up - Too - The pressure build up during crank- O
Slow ing is too slow.
- Check the IMV wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P0255 IMV Driver Circuit Mal- - IMV driver circuit malfunction: Open O O
function - Open - Check the IMV wiring harness.
• Check the ECU pin #87 for open.
- Check the ECU wiring harness.
- Check the IMV resistance.
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P0251 IMV Driver Circuit Mal- - IMV driver circuit malfunction: Short O O
function - Short - Check the IMV wiring harness.
• Check the ECU pin #87 for short.
- Check the ECU wiring harness.
- Check the IMV resistance.
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P0253 IMV Driver Circuit Mal- - IMV driver circuit malfunction: Short O O O
function - Short to Ground to ground
- Check the IMV wiring harness.
• Check the ECU pin #87 for short
to ground.
- Check the ECU wiring harness.
- Check the IMV resistance.
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 33

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
- The intake air temperature sensing
value is lower than maximum value
of 150°C: Open

ECU
- Check the supply voltage to sensor.
• Actual air temperature vs. Voltages
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the sensor wiring harness.
• Check the source power circuit
for short to ground.
- Check the sensor resistance.
• Actual air temperature vs. Resis-
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the ECU wiring harness.
• Check the ECU pin #64 and #84
for open.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
34 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0112 Intake Air Temperature Cir- - The intake air temperature sensing
cuit Malfunction - Open value is lower than maximum value
of 150°C: Open
- Check the supply voltage to sensor.
• Actual air temperature vs. Voltages
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the sensor wiring harness.
• Check the source power circuit
for short to ground.
- Check the sensor resistance.
• Actual air temperature vs. Resis-
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the ECU wiring harness.
• Check the ECU pin #64 and #84
for open.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 35

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0110 Intake Air Temperature Cir- - The intake air temperature sensing
cuit Malfunction - Source value is lower than minimum value or
Power Problem higher than maximum value, or the ex-

ECU
ternal power to HFM sensor is faulty.
- Check the supply voltage to sensor.
• Actual air temperature vs. Voltages
• 20°C: 2.65 Ω
• 30°C: 2.18 Ω
• 50°C: 1.40 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the sensor wiring harness.
• Check the source power circuit
for short to ground.
- Check the sensor resistance.
• Actual air temperature vs. Resis-
tance
• -40°C: 39.260 Ω
• -20°C: 13.850 Ω
• 0°C: 5.499 Ω
• 20°C: 2.420 Ω
• 40°C: 1.166 Ω
• 60°C: 0.609 Ω
• 80°C: 0.340 Ω
• 100°C: 0.202 Ω
• 120°C: 0.127 Ω
• Recovery values when intake air
temperature sensor failure: 50°C
- Check the ECU wiring harness.
• Check the ECU pin #64 and #84
for open and short.
- Replace the ECU if required.
P1171 #1 Injector MDP Malfunction - The #1 injector MDP is faulty.
- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition
try again
- Replace the injector and perform C2I
coding again.
P1172 #2 Injector MDP Malfunction - The #2 injector MDP is faulty.
- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition
try again
- Replace the injector and perform C2I
coding again.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
36 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1174 #4 Injector MDP Malfunction - The #4 injector MDP is faulty.
- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition
try again
- Replace the injector and perform C2I
coding again.
P1175 #5 Injector MDP Malfunction - The #5 injector MDP is faulty.
(only D27DT) - C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition
try again
- Replace the injector and perform C2I
coding again.
P1173 #3 Injector MDP Malfunction - The #3 injector MDP is faulty.
- C2I coding check
- Check fault code
- No fault condition, vehicle speed 70 KPH
- Coolant temp. 75°C above condition
try again
- Replace the injector and perform C2I
coding again.
P1252 Too High IMV Pressure - The rail pressure is excessively high.
- Check the IMV wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #87 for open
and short.
- Check the rail pressure sensor.
• Supply voltage: 5 ± 0.1 V
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the transfer pressure fuel lines.
• Check the fuel level in fuel tank.
Check the fuel system for air influx.
• Check the fuel filter specification.
- Check the high pressure fuel system.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the IMV resistance: 5.44 Ω
• When out of specified value: re-
place high pressure pump and IMV
- Replace the ECU if required.
P1120 Accelerator Pedal Sensor - The potentiometer 1 is not plausible O
#1 Malfunction with potentiometer 2.
- Check the supply voltage to sensor.
- Check the wiring harness.
• Check the ECU pin #71, 53 and
#32, 14 for open and short.
- Check the accelerator pedal module.
- Check the ECU wiring harness.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 37

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1121 Accelerator Pedal Sensor - The potentiometer 2 is not plausible O O
#2 Malfunction with potentiometer 1.
- Check the supply voltage to sensor.

ECU
- Check the wiring harness.
• Check the ECU pin #71, 53 and
#32, 14 for open and short.
- Check the accelerator pedal module.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1122 Accelerator Pedal Sensor - When triggering limp home mode. O O
Malfunction (Limp Home - Check the supply voltage to sensor.
Mode)
- Check the wiring harness.
• Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
- Check the accelerator pedal module.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1123 Accelerator Pedal Sensor - When triggering reduced torque mode. O O
Malfunction (Reducde Torque - Check the supply voltage to sensor.
Mode)
- Check the wiring harness.
• Check the ECU pin #72, 71, 53 and
#57, 32, 14 for open and short.
- Check the accelerator pedal module.
- Check the ECU wiring harness.
- Replace the ECU if required
P1124 Accelerator Pedal Sensor - The accelerator pedal sensor is stuck. O
Malfunction - Stuck - Check the brake switch wiring har-
ness and operations.
- Check the accelerator pedal operations.
- Check the accelerator pedal module.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0122 Accelerator Pedal Sensor - Out of range about potentiometer 1 O O
#1 Malfunction - Open of pedal sensor: lower than speci-
fied values
- Check the supply voltage to sensor.
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #71, #53 for
open and poor contact.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0123 Accelerator Pedal Sensor - Out of range about potentiometer 1 O
#1 Malfunction - Short of pedal sensor: higher than speci-
fied values
- Check the supply voltage to sensor.
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #71, #53 for
short and poor contact.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
38 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0120 Accelerator Pedal Sensor - The 5 V supply voltage is faulty. O
#1 Malfunction - Supply - Check the supply voltage to sensor.
Voltage Fault
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #72, #53 for
open and short.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0222 Accelerator Pedal Sensor - Out of range about potentiometer 2 O O
#2 Malfunction - Open of pedal sensor: lower than speci-
fied values
- Check the supply voltage to sensor.
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #32, #14 for
open and poor contact.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0223 Accelerator Pedal Sensor - Out of range about potentiometer 2 O
#2 Malfunction - Short of pedal sensor: higher than speci-
fied values
- Check the supply voltage to sensor.
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #32, #14 for
short and poor contact.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0220 Accelerator Pedal Sensor - The 2.5 V supply voltage is faulty. O
#2 Malfunction - Supply - Check the supply voltage to sensor.
Voltage Fault
- Check the wiring harness.
• Check the circuit for open and short.
• Check the ECU pin #57, #14 for
open and short.
- Check the accelerator pedal.
- Check the ECU wiring harness.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 39

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0192 Fuel Rail Pressure Sensor - The fuel rail pressure sensing values O
Malfunction - Open are lower than specified values.
• Minimum sensing values: - 112 bar

ECU
(Open)
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #25, #26 for
open and poor contact.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.
P0193 Fuel Rail Pressure Sensor - The fuel rail pressure sensing values O
Malfunction - Short are higher than specified values.
• Maximum sensing values: 1,600
bar (Short)
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055±
0.125V
• Output voltage at atmospheric
pressure: 0.5±0.04V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #25, #26 for
short and poor contact.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.
P0190 Supply Voltage Fault to - The supply voltage to fuel rail pres- O
Fuel Rail Pressure Sensor sure sensor is faulty.
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055±
0.125V
• Output voltage at atmospheric
pressure: 0.5±0.04V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #6, #26 for
open and short.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN
40 ECU

Torque Torque Delayed Immediately Limp

DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0191 Fuel Rail Pressure Sensor - The rail pressure drop is too high. O O
Signal Fault - Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #6, #26 for
open and short.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.
P1192 Fuel Rail Pressure Sensor - The rail pressure sensor initial val- O
Initial Signal Fault - Low ues are lower than specified values
with the ignition “ON”.
• Minimum sensing values: - 9 0
bar (Open)
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #25, #26 for
open and poor contact.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.
P1193 Fuel Rail Pressure Sensor - The rail pressure sensor initial val- O
Initial Signal Fault - High ues are higher than specified values
with the ignition “ON”.
• Maximum sensing values: 90 bar
(Short)
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #25, #26 for
short and poor contact.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
ACTYON SM - 2006.03 EFFECTIVE DATE
AFFECTED VIN
 ECU 41

Torque Torque Delayed Immediately Limp

SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1190 Fuel Rail Pressure Sensor - The rail pressure sensor initial val- O O
Initial Signal Fault ues are higher or lower than speci-
fied values with the ignition “ON”.

ECU
• Maximum sensing values: 90 bar
(Short)
• Minimum sensing values: - 90
bar (Open)
- Check the supply voltage to sensor.
• Output voltage at 1600 bar: 4.055
± 0.125 V
• Output voltage at atmospheric
pressure: 0.5 ± 0.04 V
- Check the sensor and ECU wiring
harness.
• Check the ECU pin #25, #26 for
open and short.
• Check the fuel rails and high pres-
sure pipes for leaks.
- Check the fuel rail pressure sensor.
- Replace the ECU if required.
P0215 Main Relay Fault - Stuck - The main relay is stuck ; Shut down.
- Resistance of main relay: 92 Ω ± 9 Ω
(at 20°C)
- Check the main relay wiring harness.
- Check the ECU wiring harness.
• Check the ECU pin #3, 4, 5 for open
and short.
- If the forced operation is not available,
replace the ECU.
- Check the fuse for main relay
P1500 Vehicle Speed Fault - The vehicle speed signal through CAN
communication is faulty.
- Check the CAN communication line for
open and short.
- Check the ABS/ESP and TCU commu-
nication lines.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0642 ECU Supply Voltage 1 - Malfunction reference supply voltage
Fault - Low (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1
- Check the wiring harnesses.
- Replace the ECU if required.

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0643 ECU Supply Voltage 1 - Malfunction reference supply voltage
Fault - High (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1
- Check the wiring harnesses.
- Replace the ECU if required.
P0641 ECU Supply Voltage 1 - Malfunction reference supply voltage
Fault (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1
- Check the wiring harnesses.
- Replace the ECU if required.
P0652 ECU Supply Voltage 2 - Malfunction reference supply voltage O O O
Fault - Low (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pres-
sure sensor, cam sensor
- Check the wiring harnesses.
- Replace the ECU if required.
P0653 ECU Supply Voltage 2 - Malfunction reference supply voltage O O
Fault - High (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pres-
sure sensor, cam sensor
- Check the wiring harnesses.
- Replace the ECU if required.
P0651 ECU Supply Voltage 2 - Malfunction reference supply voltage O O
Fault (5 V) from ECU
• Supply voltage: 5 V
- Check the supply voltage to each
sensor
• Supply voltage (5 V): accelerator
pedal sensor 1, HFM sensor, rail
pressure sensor, booster pres-
sure sensor, cam sensor
- Check the wiring harnesses.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0698 ECU Supply Voltage Fault - Malfunction reference supply voltage
- Low (2.5 V) from ECU
• Supply voltage: 2.5 V

ECU
- Check the supply voltage to each
sensor
• Supply voltage (2.5 V): accelera-
tor pedal sensor 2
- Check the wiring harnesses.
- Replace the ECU if required.
P0699 ECU Supply Voltage Fault - Malfunction reference supply voltage
- High (2.5 V) from ECU
• Supply voltage: 2.5 V
- Check the supply voltage to each
sensor
• Supply voltage (2.55 V): accelera-
tor pedal sensor 2
- Check the wiring harnesses.
- Replace the ECU if required.
P0697 ECU Supply Voltage Fault - Malfunction reference supply voltage
(2.5 V) from ECU
• Supply voltage: 2.5 V
- Check the supply voltage to each
sensor
• Supply voltage (2.55 V): accelera-
tor pedal sensor 2
- Check the wiring harnesses.
- Replace the ECU if required.
P0245 Turbo Charger Actuator - The waste gate driver circuit is short O
Circuit Fault - Short to ground or open
- Check the actuator wiring harness.
- Check the solenoid valve.
- Check the ECU wiring harness.
• Check the ECU pin #95 for open
and short.
- Replace the ECU if required.
P0246 Turbo Charger Actuator - The turbo charger actuator power O O
Circuit Fault - Short to B+ source circuit is short.
- Check the actuator wiring harness.
- Check the solenoid valve.
- Check the ECU wiring harness for
short and poor contact.
- Replace the ECU if required.
P0606 ECU Watchdog Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1607 ECU Injector Cut Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1600 ECU Shut Down Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1601 ECU Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1602 ECU Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1614 ECU C2I/MDP Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check C2I code
- Check the ECU.
- Replace the ECU if required.
P1615 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1616 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1606 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1620 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1621 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P1622 ECU Fault - The ECU is defective. O O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1148 Accelerometer (Knock - Check if the MDP is successful. O
Sensor) Learning Fault - Check the accelerometer (knock
sensor) sensor and wiring harness.

ECU
- Replace the ECU if required.
P0400 EGR Control Valve Fault - When the EGR emission is more than
specified value.
• The EGR controller circuit is open
or short to ground.
• The EGR controller is short to
battery.
- Check the EGR actuator wiring harness.
- Check the supply voltage to EGR so-
lenoid valve.
- Check if the EGR valve is stuck.
- Check the resistance of EGR valve:
15.4 Ω.
- Check the ECU wiring harness.
• Check the ECU pin #96 for open
and short.
P1235 VGT Operation Fault - The boost pressure control is faulty. O
- Check the air intake system.
- Check the supply voltage to sensor.
- Check the wiring harness and the
ECU wiring harness.
- Replace the ECU if required.
P1608 ECU Fault - The ECU is defective. O
- Check the chassis ground wiring
harness.
- Check the ECU.
- Replace the ECU if required.
P0335 No Crank Signals - Refer to P0372. O
P1170 Torque Trim Fault - High - Refer to P0372.

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1676 Glow Plug Communication - The communication between ECU and
Fault glow controller is faulty.
- Check the communication line be-
tween ECU and glow controller.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1 Ω.
- Check the glow controller.
- Check the ECU wiring harness.
• Check the ECU pin #34 for short to
ground.
- Replace the ECU if required.
P1677 Glow Plug Controller Fault - glow controller is faulty.
- Check the communication line be-
tween ECU and glow controller.
- Check the glow plug wiring harness.
- Check the resistance of glow plug:
below 1Ω.
- Check the glow plug relay.
- Check the ECU wiring harness.
• Check the ECU pin #34 for short to
ground.
- Replace the ECU if required.
P0671 #3 Glow Plug Fault - Open - The glow plug circuit is open.
- Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0672 #4 Glow Plug Fault - Open - The glow plug circuit is open.
- Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0673 #5 Glow Plug Fault - Open - The glow plug circuit is open.
- Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.

DIAGNOSIS CHANGED BY
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P0674 #1 Glow Plug Fault - Open - The glow plug circuit is open.
- Check the communication line be-
tween ECU and each glow plug.

ECU
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0675 #2 Glow Plug Fault - Open - The glow plug circuit is open.
- Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1671 #3 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω.
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1672 #4 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1673 #5 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P1674 #1 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1 Ω
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.

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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1675 #2 Glow Plug Fault - Short - The glow plug circuit is short.
(B+) - Check the communication line be-
tween ECU and each glow plug.
- Check each glow plug wiring harness.
- Check the resistance of each glow
plug: below 1Ω
- Check or replace glow controller.
- Check the ECU wiring harness.
- Replace the ECU if required.
P0700 TCU Signal Fault - The communication between ECU and
TCU is faulty.
- Check the communication line be-
tween ECU and TCU.
- Check the ECU pin #54, 73 for open
and short.
- Replace the ECU or TCU if required.
P1540 Air Conditioner Operating - Check the air conditioner sensors and
Circuit Fault - Open wiring harnesses.
- Check the ECU wiring harness.
- Check the ECU if required.
P1541 Air Conditioner Operating - Check the air conditioner sensors and
Circuit Fault - Short wiring harnesses.
- Check the ECU wiring harness.
- Check the ECU if required.
P1542 Air Conditioner Operating - Check the air conditioner sensors and
Circuit Fault - Short to wiring harnesses.
Ground - Check the ECU wiring harness.
- Check the ECU if required.
P1149 Too High Water Level in - Drain the water from fuel filter. O
Fuel Filter
P1634 Immobilizer Fault (refer to - No response from immobilizer.
immobilizer section) - Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna.
- Replace the ECU if required.
P1635 No response from Immo- - No response from immobilizer.
bilizer (refer to immobilizer - Perform the immobilizer coding again.
section)
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna.
- Replace the ECU or immobilizer if
required.

DIAGNOSIS CHANGED BY
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SCAN
DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1630 Wrong response from Im- - The invalid key is inserted or no communi-
mobilizer (refer to immo- cation between transponder and immobi-
bilizer section) lizer (no response from transponder).

ECU
- Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P1631 Immobilizer Fault (refer to - The immobilizer is not operating.
immobilizer section) - Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P1632 Immobilizer Fault (refer to - No response from immobilizer.
immobilizer section) - Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P1633 Immobilizer Fault (refer to - No key coding.
immobilizer section) - Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P0633 Immobilizer Fault (refer to - Key memory is not available
immobilizer section) (permissible - 5).
- Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.

CHANGED BY DIAGNOSIS
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode
P1636 Immobilizer Fault (refer to - Severe trouble is not defined.
immobilizer section) - Perform the immobilizer coding again.
- Check the ECU wiring harness.
• Check the ECU pin #34 for open
and short.
- Check the immobilizer unit for open and
short or check the supply voltage.
- Check the immobilizer antenna and
transponder for damage.
- Replace the ECU if required.
P1102 High HFM Sensor Signal - HFM sensing values are higher than
specified sensing values (not circuit
failure but sensor failure).
P1103 Low HFM Sensor Signal - HFM sensing values are lower than
specified sensing values (not circuit
failure but sensor failure).
P1501 Variant coding failure - If the vehicle speed is below 15 km/h
(vehicle speed) (even over 1,600 rpm of engine speed)
when the “Vehicle speed sensor” cod-
ing is “YES” (Non-ABS vehicle), the
vehicle speed input failure appears.
- If the “Vehicle speed sensor” coding
is “NO” (CAN, ABS/ESP vehicle), the
trouble code does not appear.
- Check the “Vehicle speed sensor” coding.
P1503 Vehicle speed sensor - If the pulse from speed pulse ring is
input failure more than specified value during the
specified interval when the “Vehicle
speed sensor” coding is “YES” (Non-
ABS vehicle), the vehicle speed sen-
sor failure appears.
- Specified pulse: 52 pulses/1 revolution
- Check the “Vehicle speed sensor” coding.
P0600 CAN BUS failure - CAN related device in ECU is defective.
- CAN communication between units is
failure.
P0602 Vehicle speed sensor - Even though the ESP or TCCU is not
coding failure installed in the vehicle, the vehicle
speed signal is sent through CAN
communication.
P0608 ABS/ESP coding failure - ABS/ESP variant coding is failure.
- CAN communication is failure.
P0613 TCU coding failure - TCU variant coding is failure.
- CAN communication between units is
failure.
P0644 CAN cluster failure - CAN cluster is failure.
- CAN communication between units is
failure.

DIAGNOSIS CHANGED BY
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DTC Trouble Help Reduction Reduction Engine Engine Home MIL
(max.50%) (max.20%) Stop Stop Mode

ECU
P1565 Auto cruise switch - Auto cruise acceleration switch or
failure (Acceleration) related wiring harness is defective.
P1566 Auto cruise switch - Auto cruise OFF switch or related
failure (OFF) wiring harness is defective.
P1567 Auto cruise switch - Auto cruise switch or related wiring
failure harness is defective.
P1568 Auto cruise switch - Auto cruise deceleration switch or
failure (Deceleration) related wiring harness is defective.
P1569 Auto cruise switch - Auto cruise safety switch or related
failure (Safety) wiring harness is defective.
P3040 ECU internal failure - ECU internal failure
P3041 ECU internal failure - ECU internal failure
(only D27DT)
P1657 Engine mount control - Engine mount level control circuit is
failure (Open) failure.
P1658 Engine mount control - Engine mount level control circuit is
failure (Short to B+) short to B+.
P1659 Engine mount control - Engine mount level control circuit is
failure (Short to ground) short to ground.
P0805 Abnormal neutral signal - The “Neutral” signal from manual
transmission is sent to CAN cluster.
Then, CAN cluster sends this signal
to ECU via CAN communication line.
- ECU cannot determine where the sig-
nal problem is; in neutral switch, wir-
ing or CAN communication line.
- Check the neutral switch wiring
harness.

CHANGED BY DIAGNOSIS
EFFECTIVE DATE ACTYON SM - 2006.03
AFFECTED VIN